First steps
- Map the value stream with inventory counts.
- Set pull loops with limits.
- Reduce batch size step by step.
How to measure success
Inventory days and lead time. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- Value stream mapping: A problem at one machine.
- Kanban / pull: Very irregular, one-off demand.
- SMED: Lines that rarely change over.
- Heijunka (levelling): Plants where changeovers are still long; do SMED first.
- One-piece flow: Processes with long batch steps (heat treatment, painting).
The methods in one line
| Method | What it is |
|---|---|
| Value stream mapping | Maps material and information flow end to end and shows waiting, inventory and lead time. |
| Kanban / pull | Replenishes material by actual consumption with cards or signals and fixed limits. |
| SMED | Shortens changeovers by moving work outside the machine stop and simplifying the rest. |
| Heijunka (levelling) | Levels the mix and volume over the day so the line and suppliers see a steady demand. |
| One-piece flow | Moves parts one at a time between stations to cut lead time and find defects immediately. |