Lean Manufacturing: the importance of call buttons

Lean Manufacturing aims to eliminate waste. Call buttons are an essential tool to achieve this.

The 7 wastes and call buttons

Among the 7 Muda (wastes), waiting is particularly targeted by call buttons. An operator waiting for help, a machine stopped for lack of maintenance... So much avoidable loss.

The Jidoka principle

Jidoka (autonomation) allows each operator to stop production as soon as a problem is detected. The call button is the concrete tool of Jidoka.

Our system for Lean:

• LC-B5 multi-touch buttons (quality problem / maintenance need / stop)
• Visual alarms by zone
• Pagers for support teams
• Real-time dashboard

Progressive implementation

1. Identify critical stations 2. Install call buttons 3. Train teams 4. Measure response times 5. Continuously improve

Key indicators

• Average response time (target: < 3 minutes)
• Number of calls per station
• First call resolution rate

Conclusion

Call buttons are much more than a communication tool: they are the symbol of a culture of immediate problem resolution.