First steps
- List critical machines and their critical parts.
- Set min / max from consumption.
- Review slow movers yearly.
How to measure success
Downtime waiting for parts and stock value. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- Weibull analysis: Defects found at the end of line.
- Kanban / pull: Very irregular, one-off demand.
- Pareto chart: A single defect type with one known cause.
- 5S: Process capability problems.
The methods in one line
| Method | What it is |
|---|---|
| Weibull analysis | Models failures over time or mileage: early failures, random failures or wear-out. |
| Kanban / pull | Replenishes material by actual consumption with cards or signals and fixed limits. |
| Pareto chart | Ranks defect types or causes so the team works on the vital few first. |
| 5S | Workplace organisation: sort, set in order, shine, standardise, sustain. |