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Innovative solutions to error-proof manufacturing

lean production was first used to describe the Japanese automotive industry in the 1970s and 1980s. Specifically, how Toyota was producing more goods with less space, fewer people, less capital and less inventory. Lean Thinking Le Commonly Used Error-Proofing Terms Lean thinking is a term for applying practices that reduce waste in any kind of business—healthcare, banking, software development, customer service, fast food, and so on. It expands the concept of lean production—which applies to automotive production and other manufacturing enterprises—to the areas of order processing, product development, warehousing, distribution and retailing. The term Andon Bin picking or part picking lights on machines or production lines indicate operation status. They are often located overhead for workers or a supervisor to view them. is the task of removing parts from a bin or other container, during product assembly or order fulfillment. Error proofing or mistake proofing Just in Time (JIT) Kaizen is the continuous incremental improvement of an activity or product to eliminate waste. is an inventory management system in which the supplier delivers raw materials or components just before they are needed in a manufacturing process. is designing processes to either prevent mistakes from happening or detect mistakes before they move further down the line. Lean manufacturing or smart manufacturing refers to initiatives for eliminating waste in manufacturing processes. Pick-to-light is a system in which each pick location is connected to a light; software turns on the light where the next pick is. Poka-yoke Sequential part selection is a Japanese term for mistake proofing. A poka-yoke is any device that prevents incorrect parts from being made or assembled, or easily identifies a mistake right after it is made. is the selection of parts in the sequence in which they are added to an assembly. Going Lean Six Sigma is a methodology that provides the techniques and tools to improve the capability and reduce the defects in any process. Lean is not a single solution, but a combination of small changes that add up to a big difference. It requires a never-ending process of evaluation and refinement. Businesses developing a lean system that suits their enterprises consider the following:• What happens between discreet processes—between Task A and Task B? • How are processes arranged in a factory to save floor space—should Task A be next to Task B, or next to Task Z?• How does the chain of processes work as a system—how do all the processes flow? • How does each worker perform a task? The goal is to minimize wasted effort and eliminate mistakes. Lean considers the human factor: how people and technology are combined to make the most of the strengths of both and minimize their weaknesses. Zero Quality Control (ZQC) is an approach to quality management that relies heavily on the use of poka-yoke devices. The Role of Pick-to-Light Pick-to-light systems reduce human error, reducing defects and the risk of expensive product recalls. Some key points include the following:• Sequential assembly lights prevent erroneous assembly, eliminating problems down the line.• Call lights are communication tools that keep production running without each worker having a large inventory nearby. As a result, work areas can be smaller, reducing the overall floor space needed.• Pick lights guide workers to the correct bin, saving time. • Indicator lights fit into the work cell, so the worker does not have to spend time and energy to step outside the work cell to check a stack light. And they are small, saving space.
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