LEAN TOOLS

20 Lean Essential Tools

LEAN TOOLS
 LEAN TOOLS
1. Pull Production System dan JIT
2. Kanban

3. Visual Management System

4. Andon

5. Poka Yoke
PENDAHULUAN
 Lean Production is an integrated set of activities designed to
achieve production using minimal inventory of raw materials
(bahan mentah), work in process (barang setengah jadi, barang
yang masih perlu diolah lagi) and finished good (produk
akhir/barang jadi).
 Dalam Lean Production , kebutuhan produksi dibuat berdasarkan
permintaan aktual (actual demand) terhadap produk tsb.
 Dalam Lean , produk hanya diproduksi berdasarkan keinginan
pelanggan : berapa jumlah nya , kapan harus diproduksi dan
dikirimkan , bagaimana kualitasnya.
1. PULL PRODUCTION SYSTEM
 Pull secara bahasa artinya tarik
 "Pull type" means Make To Order in which the production is based on
actual demand.
 Pull merupakan proses operasi mulai dari tahap pembelian hingga
delivery customer yang mengikuti arah pasar.
 Sistem pull sebagai prinsip operasi JIT
 Perencanaan manufaktur pada sistem pull ini adalah berdasarkan
tarikan (pull) permintaan aktual pelanggan.
 Peramalan permintaan (forecast) pada sistem pull masih digunakan
sebagai konsensus antara stakeholders (pelanggan, pemasok, dan
manufaktur),
 Konsensus ini diperlukan agar ada kesepahaman tentang kapasitas
sistem dan jumlah kanban untuk menjaga kelancaran rantai pasok
 Dalam dunia nyata, kurang tepat juga apabila dikatakan dalam
sistem pull tidak ada persediaan (zero inventory), proses produksi
dalam sistem pull mengalir dengan ekspektasi persediaan sekecil
mungkin (few inventory).
 PUSH PRODUCTION SYSTEM

Marketing
Production Kanban Withdrawal Kanban (Customer
Demand +
Forecasting)
Kanban Kanban

Upstream Downstream
Process Product Product Process

Supermarket
PULL PRODUCTION SYSTEM
PULL PRODUCTION
PULL-ENABLING TOOLS

• Takt Time
• Line Balance
• Kanban
• Visual displays
• Supermarkets
• Water beetles and milk runs
PULL VS PUSH
JIT
 JIT means producing what is need when needed and no
more.
 Just-In-Time (JIT), yaitu sistem produksi yang membuat
(mengirimkan) produk yang dibutuhkan pada waktu dan
jumlah yang dibutuhkan sehingga mempertinggi efisiensi
dan memungkinkan respon yang cepat untuk perubahan.
IN PULL AND JIT
 Kanban berasal dari bahasa jepang yang berarti
signal or instruction card.
 Kanban (カンバン?), berarti sinyal,

 Kanban bukanlah sistem pengontrol persediaan,

namun merupakan sistem pengaturan yang
membantu menentukan apa, kapan, dan berapa
banyak sebuah produk harus dibuat.
 Kanban digunakan production scheduling yang
untuk mentrigger kapan barang harus
diproduksi dan berapa banyak.
KANBAN (SIGNAL OR INSTRUCTION CARD)
KANBAN
VISUAL MANAGEMENT
 The VM concept is designed to allow ANYONE entering the
workplace, including those unfamiliar with the workplace,
product or processes, understand what's going on, to understand
it and so see whats under control and what isnt
 Allows management to immediately experience the performance
of the business as they walk through the workplace and not
simply read about it in reports at the end of the month.
 The detail displayed varies from business to business (even
department to department) . Materi yang ditampilkan bisa
bermacam-macam sesuai dengan main core bussiness dari
department masing-masing.
 VM extends the concept to include the 5 P's or 5 M
VM CONCEPT
VISUAL MANAGEMENT
VISUAL MANAGEMENT
VISUAL MANAGEMENT
VISUAL MANAGEMENT
VISUAL MANAGEMENT
VISUAL MANAGEMENT
ANDON
 Andon (Japanese: アンドン or あんどん or 行灯) is a manufacturing term referring to a
system to notify management, maintenance, and other workers of a quality or process
problem.
 The centerpiece is a device incorporating signal lights to indicate which
workstation has the problem.
 The alert can be activated manually by a worker using a pullcord or button, or
may be activated automatically by the production equipment itself.
 The system may include a means to stop production so the issue can be
corrected.
 Some modern alert systems incorporate audio alarms, text, or other displays.
 It gives the worker the ability, and moreover the empowerment, to
stop production when a defect is found, and immediately call for
assistance.
 Common reasons for manual activation of the Andon are part
shortage, defect created or found, tool malfunction, or the
existence of a safety problem.
 Work is stopped until a solution has been found.
 The alerts may be logged to a database so that they can be studied as
part of a continuous-improvement program
ANDON
ANDON
ANDON