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Chapter 4: Lean Concepts - Coggle Diagram

- - - - Tracks worker movement paths
      - Requires:
        
        Workspace map (bird’s eye)
        
        Furniture/equipment layout
        
        Observing actual movement
      - Reveals:
        
        Repeated motion
        
        Inefficient layouts
        
        Bottlenecks
    - - Must analyze:
        
        Time
        
        Movement frequency
        
        Cost impacts
      - Helps justify process improvements
  - - - Lower labor cost
      - Reduce fatigue
      - Improve speed & flow
      - Optimize workstation design
- - - - Poor coordination between steps
      - Unreliable processes
      - Oversized batch work
      - Rework cycles
      - Long changeovers (people or machines)
- - - - Type I Muda
        
        Non-value-added tasks that might be required by circumstances
        
        Make essential muda as efficient and cost-effective as possible
      - Type II Muda
        
        Non-value-added tasks that can be removed immediately
        
        Rearrange workflow → reduce waste without changing the product itself
  - - - Sort (Seiri) – Remove unneeded items; keep only necessary resources
        
        Phase 1
        
        Benefits:
        
        Eliminates obstacles, costs, time, and frustration
        
        Applicable to digital processes too (e.g., removing unused files or applications)
      - Straighten (Seiton) – Organize tools/materials for easy access
        
        Digital applications
        
        Shared desktops with same programs & icons
        
        Reduces time searching for software
      - Shine (Seiso) – Clean workspace; maintain order
        
        Digital application
        
        Properly name files
        
        Maintain folder structures
        
        Delete/archive unnecessary files
      - Standardize (Seiketsu) – Set standards for consistency in processes
        
        Maintain progress from previous phases
        
        High standards of orderliness and consistency
        
        Addresses challenge: daily work stress may disrupt order
        
        Success depends on team commitment for long-term benefits
      - Sustain (Shitsuke) – Maintain discipline to follow 5S continuously
        
        Without commitment → cycle of cleaning up after failing to maintain standard
        
        Employees must follow rules set up for standardizing and sustaining organization
        
        Benefits
        
        Reduced risks of accidents and safety issues
        
        Increased compliance with regulations (e.g., OSHA
        
        Provides foundation for additional improvements
        
        Makes waste easier to identify and eliminate
        
        Improves production and quality
        
        Overall goal: Increased profits and customer satisfaction (aligned with Six Sigma methodology)
- - - - Data producers send info directly at required intervals