In the previous article, we discussed how the efectivo system supports the implementation of Lean Manufacturing tools such as 5S, TPM, and Six Sigma. This part will focus on other key Lean methods: Kaizen, SMED, Standardized Work, and TWI. We will show how the efectivo system, using RTLS technology, helps in their practical application and optimization of processes in manufacturing companies following the Lean Manufacturing philosophy.
Lean Manufacturing – What Is It?
We have presented an introduction to the topic of lean manufacturing in detail here . However, let's briefly remind you what Lean Manufacturing is. It is a production management philosophy that aims to continuously improve processes, and Lean Manufacturing tools are used to eliminate waste.
Key Lean methods, such as Kaizen, SMED, Standardized Work, and TWI, among others, allow you to increase operational efficiency and the quality of manufactured products. The efectivo system, based on RTLS (Real-Time Location System) technology, supports companies in the implementation of these tools, offering process monitoring, data analysis, and automation of activities.
Other Lean methodologies supported by RTLS efectivo are discussed in the first part of the cycle, available here: Lean Manufacturing Tools (5S, TPM, Six Sigma).
Kaizen in Lean Management – Continuous Improvement
Kaizen means continuous improvement and involving all employees in improving processes and eliminating waste. This philosophy is based on the gradual introduction of small improvements. The efectivo system supports the implementation of Kaizen principles by using RTLS technology and analytical modules, providing data on operational efficiency and enabling the monitoring of changes introduced as part of improvement initiatives.
How Does Efectivo Support Kaizen?
The main principles of Kaizen include Continuous Improvement, Employee Involvement, Small, Incremental Changes, Focus on Processes, Measurement and Analysis, and Standardization. The efectivo system supports these principles in the following ways:
- Capture ideas and analyze the effects of changes – In the efectivo app, employees can submit ideas for improvements, which are then analyzed based on the data collected by RTLS. For example, efectivo allows employees to report areas that need attention using the function button on the tag, making it easy to quickly spot areas for improvement.
- Monitoring of implemented changes – Access to ready-made reports allows managers to track whether new procedures are being followed and how efficient they are.
- Motivating employees to Kaizen – Efectivo allows you to reward employees for reporting improvements through a motivation system based on e-coins, available in the application.
- Identification of inefficiencies and waste - Thanks to the analysis of reports, such as the Spaghetti chart, Heat Map or the report of the distance traveled, it is possible to identify waste and effectively optimize selected processes. Efectivo allows you to monitor and analyze the actual flow of resources and employees. Identifying inefficient routes allows you to optimize them by making small changes.
- Space Optimization - The Heat map report indicates high-traffic areas, making it easy to reorganize spaces for greater efficiency.
- Improved communication with employees – The system enables effective communication, including about new procedures through the chat function and the ability to share documents with employees in the efectivo application.
Example:
In an automotive production plant, it has been noticed that employees often move between positions, wasting time. After analyzing the data from the RTLS system, changes were made to the layout of the stations, reducing the time of internal transport by 15%. Each employee who follows the new arrangement receives additional points in the incentive system.
SMED – Shortening Changeover Times With Efectivo
SMED (Single-Minute Exchange of Die) is a method of reducing machine changeover time, which is crucial for increasing production flexibility. The efectivo system allows you to monitor change over time, analyze data on the flow of employees and tools, and identify areas for optimization.
How Does Efectivo Support SMED?
- Measure machine changeover time – RTLS monitors the duration of each changeover and indicates where the highest delays occur.
- Operator Presence Verification – With RTLS real-time asset monitoring, you can verify that all required personnel are present at the machine during changeovers.
- Analyzing reports to implement improvements – Using the efectivo reporting system to optimize the changeover process based on historical data.
- Spaghetti diagram
- Tracking the actual flow of employees and tools during changeover allows you to identify situations that need optimization.
- Document and analyze resource flows to design support systems such as mobile workstations and better tool placement.
- Heat map
- An analysis of the places where employees move most often indicates the possibility of performing some activities outside the machine.
- Identification of the most frequently used routes and places indicates the need to standardize the layout of space.
- Traveled Distance Report
- Monitoring the distance traveled by workers during changeovers helps identify activities that can be performed before the machine is stopped.
- Asset Speed Report
- Analyzing the speed of movement of employees and assets indicates the possibility of optimizing their movement and performing external activities.
- Distance Report Between Two Assets
- Determining optimal distances between assets allows you to reduce preparation and travel time.
Example:
In a packaging company, analyzing data from the RTLS system, it was shown that 20% of the changeover time was waiting for tools. A system of early preparation of tool sets was introduced, which significantly shortened the changeover time.
Standardized Work – Maintaining High-quality of Operations
Standardized work involves unifying and documenting operational best practices. Efectivo helps in its implementation by controlling the compliance of employees' activities with the set goals and procedures.
How Does Efectivo Support Standardized Work?
- Sequence Monitoring – RTLS records whether employees perform tasks in a specific order.
- Tasks for employees – The mobile application informs employees about assigned operational tasks.
- Reporting deviations from the standard – Deviations from the established procedures are detected in the reporting systems and reported to the manager. Reports such as the Spaghetti Diagram and Heat Maps help managers document the most effective routes and working methods, making it easier to create accurate and practical standardized work instructions. On the other hand, analysis of the Spaghetti, Distance traveled and Resource Speed reports can reveal inefficient sequences of operations that need to be optimized.
Example:
In a production plant, the employee had to return to the same place many times. Based on efectivo reports, the process was reorganized in such a way as to reduce the number of employee returns. The system measured the time and distance traveled and helped to determine the optimal sequence of operations.
TWI Method – Effective Employee Training
TWI (Training Within Industry) is a training method that aims to onboard new employees quickly and effectively. Efectivo supports TWI by automating training processes and monitoring employee progress.
How Does Efectivo Support TWI?
- Access to training materials – Employees can use user manuals, job instructions, and training materials in the mobile application.
- Verification of attendance at training – RTLS monitors whether employees actually participate in training, eliminating fictitious reporting.
- Training progress tracking – Efectivo records how new employees are doing with their tasks.
- Monitoring of danger zones and signaling of danger zones for both zones significantly increases safety, especially for new employees.
- Efficient communication with new employees thanks to chat, as well as those who do not speak Polish, thanks to the function of real-time conversation translation.
Example:
At a client from the warehouse industry, thanks to the use of efecivo, the effectiveness of training new employees significantly improved, as they had constant access to digital instructions in the mobile application.
Summary
Organizations should strive for continuous improvement and adaptation in response to changing customer needs and market conditions. In order to implement the main principles of Lean Management, many different Lean Management tools can be used, and the choice of those that will be effective for a given company depends on its specifics and needs. It is worth choosing those that will allow you to fully use their potential in given business environments.
The efectivo system is a modern tool supporting the implementation of Kaizen, SMED, Standardized Work, and TWI in manufacturing companies and more. With RTLS technology and a real-time reporting system, companies can effectively optimize their processes.
What are Lean tools and how do they work? You can read more about it here:
