Top Lean Manufacturing Tools To Optimize Your Production Process

Posted by gabbyash on February 27th, 2017

Every manufacturing unit wants to optimize their production process and maximize profits using Lean methodology.

If your factory is using lean manufacturing methodology which is not bringing the right results, you must reconsider the strategy and use high-quality lean tools. Read on to know in detail.


# 1 – 5S

5S is a lean tool which can help to organize the work. It includes:-

  • Sorting and eliminating items which are not required
  • Organize the remaining items and set them in order
  • Work area inspection
  • Write new production standard to enhance the productivity metrics.
  • Apply these standards and retrospect to further refine the manufacturing processes.

# 2 – Andon

Andon provides instant and visual feedback for the plant floor.

The tool helps the managers to instantly address any problem as it occurs on the manufacturing floor to keep the production agile and lean.

# 3 – Bottleneck Analysis

It analyzes and improves the total throughput by strengthening the ‘weak links’ (part of the process that limits performance).



# 4 – Continuous Flow

Continuous Flow ensures to eliminate any form of waste including inventory, waiting time, and transportation.

Hence, the tool helps to remove or minimize the ‘buffers’ between the steps of the manufacturing process.

# 5 - Gemba

Gemba is a lean philosophy which promotes managers and supervisors to spend more time on the floor.

It helps them to get a deep understanding of the real-world production issues and find associated solutions.



# 6 – Heijunka

Heijunka is a particular form of production scheduling to reduce lead times for repeat product/variant production and inventory size.

# 7 – HoshinKanri

HoshinKanri helps the manufacturing units to align the goals of the company strategy with right tactics and actions.

Once the goals are aligned, you can maintain consistent and thorough progress towards them using this tool.

# 8 – Jidoka

Jidoka helps to reduce unnecessary labor costs and improve quality all-the-time.



# 9 – Just-In-Time

Just-in-time helps to reduce inventory levels and improve cash flow. It also helps to reduce any space requirements.

#10 – Kaizen

Kaizen promotes lean teamwork so that employees can work together to achieve regular and incremental improvements in the manufacturing process.


It is advisable to hire a Six Sigma and Lean methodology practitioner before using these tools.

The practitioners will analyze the current manufacturing processes and use their past experience to hand-pick the right lean manufacturing tool. It will definitely increase the profitability and improve the business bottom-line.

For More Info Visit Here :-  How to Make Lean Manufacturing Success

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