A good tool for cutting losses is the Synchronized Production System (SPS). It begins with a tool that is discussed in the previous section: 5/6S. A clean tidy work floor is essential in this method. Too many tools at one production step will cause losses. You won’t find the right tool swiftly, it is harder to clean causing dirt to accumulate, etc. Another point of view of SPS is that if people dress sloppy than they will also produce sloppy, which leads to yield losses.

Every production step needs to be sequenced with the next. This results in less waiting times. This is not reached by entering buffers. The amount of buffers should be minimized. Without synchronized production steps SPS is not possible.

Working in batches should be minimized (this is not possible with all processes eg injection moulding). At this day in time costumers want diversification of products. People want to give their own identity to a product. Cars, bikes, computers, IPod’s, etc are . This is why flexible production steps are needed. Production is base done costumer specifications. Full warehouses with products means money in places were it has no use.These are only a few steps of the complete process. It gives however a feeling how much there is to gain in your production facility.

In every facility there are options to eliminate losses.