Mechanization

The video above is from Lean Strategies International LLC's Quick Changeover with REDUCE course.

To mechanize is to equip with machinery.  Mechanization is a last resort and should only be performed when every possible effort has been made to improve your process times.  You may be wondering, why? 

​There are two main reasons outlined by Dr. Shingo and supported by many different experienced professionals:

1. Mechanization will not reduce your time by a substantial amount.  Rather, if every effort has first been made to improve the process, you may be able to shave another minute.
2. Mechanizing will not improve the process, only a portion of the process.  While it is true that mechanizing can improve a task or an activity within your process, it is also true that if the process is poorly, designed mechanizing alone will not be able to correct the poorly designed process and the operations found therein.  

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With these two reasons in mind, mechanization is oftentimes necessary when large equipment or heavy items are part of a process.  Some practical techniques that can be used are:

• Using forklifts to move heavy items and insert tooling.
• Tightening and loosening items.
• Use of Moving Bolsters.

As you make decisions on what to mechanize and what not to mechanize, be sure that appropriate cost to benefit analysis is performed.  Mechanization will in many cases require an investment and may not be worth the amount of improvement you will get.
Challenge:

• Do you use mechanization?  Share a story about how mechanization made a positive impact on your work.  Share your thoughts in the comments section below and receive a coupon to one of Lean Strategies International LLC's courses.

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