5M For Planning

 Explore the 5M’s
 MAN
 MATERIAL
 MACHINE
 METHODS
 MONEY
Efficiency, Profitability, & The 5M’s

Profitable Manufacturing is rooted in the 5M’s of Efficiency: Manpower, Materials, Machines,
Methods, and Money. Sometimes represented as a fish diagram, the 5M’s can be used to evaluate
each process or problem in manufacturing to determine the root cause of inefficiency. At 5ME,
we think of the 5M’s as direct influences on efficient manufacturing.
The Lean Mindset

Lean Manufacturing is a shift away from the traditional model of batch processing. Lean
Manufacturing focuses on the process as a whole of machining a single part. In this way, steps
flow continuously allowing for the manufacture of a single part or thousands in rapid procession.
Lean processes hope to achieve a highly-efficient, waste-free operation, managing materials,
manpower, and energy precisely. While eliminating the risk of keeping stock in advance of
predicted orders, lean manufacturing is good for the environment, good for your employees, and
good for your bottom line. By cutting costs and freeing resources, lead times are reduced, and
both productivity and quality are improved. By adopting techniques that create incremental
improvements in the organization, a significant improvement in efficiency is seen overall.
Learn more about how each element of the 5M’s effects the efficiency of your organization.
The Role of Man in Lean Manufacturing

Skilled, Satisfied Workers Increase Efficiency
As far as manufacturing automation has come, we’ll never eliminate the need for skilled workers
in the manufacturing process. In fact, many manufacturers are finding a shortage of highly-
skilled workers with enough experience to perform today’s complex production procedures. In
order to overcome this challenge, companies must focus on maintaining the efficiency of their
workforce if they hope to increase productivity. Workers need focused, timely, and frequent
training in an environment where efficiency and productivity is a common goal.
Qualifications
There are some tasks that anyone can learn to do, but is just anyone going to do those tasks well?
Of course not! Workers with the proper training, experience, and interests will perform better
than those who are just there to get a paycheck. Finding the right workers and making sure they
are properly trained and suited to their assigned position will increase efficiency exponentially.
Experience
No amount of training can replace a worker with years of experience. It is experience that will
help workers identify and resolve problems, suggest improvements to processes, and maintain
superior efficiency. This means that experienced workers are best placed in positions that have
influence on the processes and standards around them.
Self-Discipline
Completing tasks on time with a high-level of accuracy takes practice and discipline. Employees
must work as a team towards the common goal of a lean manufacturing process. Without this
level of commitment from each employee, efficiency suffers.
Institutional Habits
Efficiency in lean manufacturing must be an institutional goal with all members of the team
invested in mutual success. In an environment where all members are focused on a common goal
inspires workers to maintain their level of commitment.
The Role of Materials in Lean

Manufacturing
Cut Costs & Increase Efficiency
In the 5M’s of efficiency, materials play an important role in the 5M’s of efficiency, often
providing a multitude of benefits including:
 Leaner material costs

 Decreased processing time
 Cleaner workpieces
 More precise products
Not to overstate the obvious, but good materials make good products. Proper selection of your
materials from base material to tooling, to metalworking fluids, will improve the quality of the
workpiece.
Quality
Sound material choices make effective products. You will prevent defective workpieces,
improve performance of the final product by selecting materials with the proper strength, weight,
and endurance. Carbon fiber composites and other commonly used hard-to-machine materials are
in high-demand because of their strength and flexibility. New technologies, like Cryogenic
Machining, make even hard-to-machine materials accessible for nearly any process.
Cleanliness
Eliminating Waste = Eliminating Expense. Between wasted raw materials, worn-out tooling, and
coating parts in contaminated, oily coolant, traditional metalworking methods are far from
efficient. By leveraging state-of-the-art materials like cryogenic cooling and efficient
manufacturing systems, you can prevent contamination of workpieces and reduce the use of
consumables like specialty cutting tools.
Performance
Superior tooling leads to better precision. Lean Manufacturing cannot be achieved with inferior
tooling. The quality, availability, flexibility of your tool assets relates directly to how adaptive
your business can be. By taking control of your tooling supply, you’ll gain precise control of
your materials and workpieces.
Environmental-Efficiency
Increase the efficiency of your manufacturing operation by maintaining a clean and healthy
environment both outside and inside your organization. Environmentally friendly materials are
characterized by:
 Reduced Waste
 Less Scrap Material
 Decreased Contamination
 Time Savings
 Energy Efficiency
 Increased Health & Safety
Technological breakthroughs like cryogenic machining cool the cutting surface of a tool to -321F
and then evaporating into harmless safe, breathable, non-greenhouse, nonflammable gas. This
green manufacturing method produces little to no waste while increasing processing speed and
tool life. Workpieces are clean and sterile without extensive coolant management systems.
The Role of Machines in Lean
Manufacturing
Efficienct Machines Increase Plant Productivity
Each machine in a manufacturing process must be precisely designed, built, and programmed to
perform its function with precision, reliability, and durability. Machines that are reliable,
durable, and efficient create a truly lean manufacturing process.
Tooling
You’ve got to have the right tools for the job at hand. Tools need to be reliable, durable, and
flexible to provide the maximum efficiency for each process. For a complete tooling system
solution, see 5ME’s extensive productivity solutions.
Work Holding
Workholding systems ensure tools are held more concentrically and accurately in the holder for
greater precision and increased tool life. The result is a better finish, less processing, and
increased cost efficiency. For a complete line of workholding solutions including air cool, liquid
cool, and storage systems, contact a machine tooling expert.
Application
Application engineering is critical to maintaining a lean manufacturing system. The best

applications incorporate careful measurement and research with detailed knowledge of the full
range of available technology to design an efficient manufacturing application. At 5ME, lean
manufacturing application engineers develop and implement, and manage applications that
incorporate every aspect of the machining process including:
 Time Studies
 Process Design
 Tooling Selection
 Application Programming
 Program Installation
 Process Training
 Application Support
 Lean Manufacturing
 Maintenance
Methods
State-of-the-Art Methods Boost Plant Efficiency
Methods used in lean manufacturing must be carefully designed and followed to maximize the
efficiency of your operation. Each step should be carefully designed to meet the specifications of
the part.
Processes
Effective process development requires extensive experience in all methods available across the
spectrum of manufacturing systems. Expert application engineers and lean manufacturing
consultants at 5ME are available to help you create the optimum process for your project.
Consultants have decades of experience working for original equipment manufacturers and
machine manufacturers. Once a process is in place, careful monitoring of its effectiveness
ensures it always performs to your expectations.
Error Proofing
If proper testing is done and processes are fully thought through and documented, it is possible to
avoid many common errors in your production process. Careful error proofing can ensure that
you have processes in place to overcome behavors that cause errors.
Statistical Process Control (SPC)
Once designed and implemented, processes are variable and must be measured, monitored, and
refined as they begin to deteriorate. Done manually, SPC is a nearly impossible task that
involves gathering and analyzing data often from multiple machines and comparing it to
application specifications.
Failure Mode Effect Analysis (FMEA)
Developed by the aerospace industry, FMEA

is a powerful tool that will analyze design,
process, and system for any manufacturing
application. Using this step-by-step process,
you can avoid all possible failures Money
Meaningful Metrics Make Manufacturing Profitable
Measurement of processes, machines, and other assets is critical to a lean manufacturing plan.
Without accurate measurement (and reporting) how will you know if your equipment is
performing at its optimal level? Measurement of the following metrics will help keep lean
processes on track and performing at their greatest efficiency and prevent bottlenecks.
 Asset Utilization  Scheduled Down Time
 Asset Availability  Delay Time
 Performance  Repair Time
 Quality  Not In-Cycle Process Time
 Plant Shut-Down Time  In-Cycle Time
Measuring Overall Equipment Effectiveness (OEE)
The combination of availability, performance, and quality, OEE is the ultimate measure of a
manufacturing process’ efficiency. This measurement quantifies how well a manufacturing unit
performs relative to its designed capacity, during the periods it is scheduled to run. Carefully
monitoring this metric will provide insight into how your materials, manpower, machinery, and
methods are affecting your operations.
Measurements are no use if they are out-of-date or too in depth to provide any useful insight.
Instead, metrics should be easily accessed in real-time, with useful analysis presented to a variety
of audiences. Only when monitoring current trends will you be able to maintain maximum
efficiency.
Powerful, Flexible Manufacturing Efficiency Software
5ME’s Freedom eWARE provides an all-inclusive software solution for monitoring OEE in real
time from anywhere you need it. A comprehensive suite of brand agnostic software integrates
with any asset to provide exceptional analysis with customizable presentation through any
Internet-ready device. Connect your entire plant with a single system, or monitor a particular cell
to prevent loss of precision.
in your manufacturing systems.

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 Explore the 5M’s

Efficiency, Profitability, & The 5M’s

The Lean Mindset

The Role of Man in Lean Manufacturing

The Role of Materials in Lean

 Leaner material costs

 Less Scrap Material

 Increased Health & Safety

Application engineering is critical to maintaining a lean manufacturing system. The best

Statistical Process Control (SPC)

Failure Mode Effect Analysis (FMEA)

Developed by the aerospace industry, FMEA

 Asset Utilization  Scheduled Down Time

 Asset Availability  Delay Time

 Performance  Repair Time

 Quality  Not In-Cycle Process Time

 Plant Shut-Down Time  In-Cycle Time

Measuring Overall Equipment Effectiveness (OEE)

Powerful, Flexible Manufacturing Efficiency Software

in your manufacturing systems.

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