Help chain: guidelines for design and operation in Lean Production Systems

Abstract Lean production aims at operational improvement by the elimination of waste and variability reduction. The lean practice known as help chain, which contributes to the lean goals is an underexplored topic. Thus, the objective of this paper is to propose guidelines regarding the help chain design and operation by addressing issues related to the definition of the events that need support from the chain and selection of the members to be involved. The proposed guidelines involve seven steps: (i) delimitation and evaluation of the scenario of application; (ii) identification and classification of abnormalities; (iii) identification of the types and contents of visual devices; (iv) identification of agents involved in the help chain; (v) definition of the operating logic of the help chain; (vi) training and qualification; and (vii) application and evaluation of the results. A partial application in the printing department of a tobacco’s manufacturer plant is a basis for discussing the strengths and weaknesses of the guidelines.