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Category Archives: Lean thinking
Planning 5s? First Know Why!
Planning 5s? First Know Why! [the broken link was removed] by Jamie Flinchbaugh The basic principle is that you must know why you want to implement 5S before being concerned about learning how to do it. Most people, when they are asked the purpose of 5S, cite safety, discipline, employee morale, reduced waste of motion and-perhaps the worst reason of all-being tour ready.All of this is wrong. The true purpose of 5S is to spot problems quickly. Very clear point. … Continue reading
Lean, Mean, Six Sigma Machines
Lean, mean, Six Sigma machines [the broken link was removed] by Tam Harbert: Without exception, each company is healthier now than it was five years ago. Three of them have turned profitable, and the fourth – Celestica – is close to turning the corner… The question is how much credit for their progress goes to Lean Six [Sigma]. Yes that is indeed a good question. What management claims as the reason for results is not necessarily actually the reason (and … Continue reading
Posted in Data, Deming, Lean thinking, Management, Management Articles, Six sigma
Tagged lean manufacturing, Six sigma
Gemba Keiei by Taiichi Ohno
Jon Miller has been posting thoughts on chapters of Gemba Keiei by Taiichi Ohno for quite some time. His latest post in on chapter 23 (of 37): Producing at the Lowest Possible Cost. The series of posts provide great doses of management wisdom. As he said in the first post: “As I re-read this book in the original Japanese, I will summarize the nuggets of wisdom from each chapter in Mr. Ohno’s book.”Some great examples, If You Are Wrong, Admit … Continue reading
Lean Software Development
I have posted on the topic of Lean Software Development previously. Lean Software Development: A Field Guide – the first 3 chapters of this new book are available online [the broken link was removed]. Excellent book that I recommended for anyone interested in lean thinking ideas. Lean Software Development: An Agile Toolkit for Software Development Managers by Mary Poppendieck and Tom Poppendieck, 2003. Articles on lean programming by the Mary Poppendieck David Carlton has an interesting post on this topic: … Continue reading
Lean Transformation Tips
The 12 Half Truths of a Lean Transformation [the broken link was removed] by Charles Hagood. A one page article reinforcing what adopting lean methods will require. The process of improving never ends. A Lean transformation has no end date! The process is ongoing and is never a closed out action item. There is no such thing as the perfect company or process, therefore the closest to perfect you can become is to recognize that it is a continuous process … Continue reading
Posted in Lean thinking, Management Articles
Lean forward
The most substantial success requires building upon the initial efforts. Truly becoming a lean organization is not something that can be done easily or quickly. And it can’t happen unless management stays focused and continues to learn about lean concepts. Continue reading
Posted in Lean thinking, Management, Management Articles
Tagged lean manufacturing
UK Lean Electronics Manufacturing
CEO viewpoint: Lean and keen manufacturing [the broken link was removed] by Eamonn Walsh, chairman and technical director of Brainboxes: At Brainboxes we have been manufacturing for 22 years so far and we believe that the way we work will keep us there. If we adopt the best practice of lean manufacturing methods and apply them to all manufacturing in the UK, electronics or otherwise, then the industry will be transformed for the good. Unreformed manufacturing will fall by the … Continue reading
Posted in Lean thinking, Management Articles, Manufacturing
Hospital Poka Yoke
Hospital Lean: Error Proofing by Mark Graban Some hospitals are making a systemic process change that they hope will prevent this error. They are banning the typical abbreviation for micrograms. They want everyone to use “mcg” for micrograms and “mg” for milligrams.Much better than telling everyone to “be careful.” Nice poka yoke example. Saving Lives: US Heath Care Improvement Going Lean in Health Care Improving the Health Care System
Posted in Health care, Lean thinking, Management, Quality tools, Systems thinking
Shigeo Shingo’s Influence on TPS
A very interesting article by Art Smalley based on an interview with Mr. Isao Kato: Shigeo Shingo’s Influence on TPS [the broken link was removed]. For those interested in the history of the Toyota Production System this article provides some excellent information. Some background on Isao Kato: As much as anyone alive Mr. Kato knows the history of TPS development from an insider’s point of view from the 1950’s forward. He also had working relationships with Mr. Ohno even more … Continue reading
Airlines Try Smarter Boarding
Airlines Try Smarter Boarding [the broken link was removed] by Dave Demerjian An airplane that spends an hour on the ground between flights might fly five trips a day,” he explains. “Cut the turnaround time to 40 minutes, and maybe that same plane can complete six or seven flights a day.” More flights mean more paying passengers, and ultimately, more revenue. Good lean thinking and faster boarding is a customer service improvement as well. Convinced that there was a statistical … Continue reading
Respect for People
A very thoughtful post, Respect for People on the Kaikaku blog raises some interesting questions. What does respect for people really mean? Toyota empowers people: To stop the line – to stop every other worker from working – that is real respect and trust. To implement creative improvement ideas around their work area. They trust you to come up with the best idea to make your work easier and more interesting. You don’t have to wait for management to tell … Continue reading
Lean Thinking Misconception
Office Furniture Companies Now Leaner [the broken link was removed] Steelcase, the largest of the nation’s office furniture companies, cut thousands of jobs, consolidated manufacturing operations and started relying more on third-party suppliers and outsourcing as it shifted toward a leaner and more flexible manufacturing model popularized by Japanese automaker Toyota Motor Corp. This does not convey true lean thinking. It is a shame so many think lean is equal to “reducing staff.” Lean is about removing waste. Removing waste … Continue reading
Posted in Lean thinking, Management Articles, Manufacturing
Tagged lean manufacturing, Lean thinking
1 Comment
Production Preparation Process
The Top 5 Reasons for Using Production Preparation Process (3P) [the broken link was removed] by Jon Miller: Production Preparation Process (3P) is one part of an overall Lean design approach that includes QFD, design reviews, and post-start up monitoring by a cross functional team to kaizen any bugs in the new system. The benefits of Production Preparation Process are a cross-functional team approach, rapid testing of ideas and the embedding of Lean manufacturing principles into process and product design.
Posted in Lean thinking, Management Articles, Quality tools
Tagged Quality tools
Most Meetings are Muda
Most Meetings are Muda (Waste) from Got Boondoggle: I will not waste your time and regurgitate all the expert based meeting protocols like following an established agenda, having a meeting plan, taking meeting notes, etc. All these ideas are great and work well. Instead, I have a list of a few meeting musts that may guide you to more productive meeting time. The post provides good tips on what to avoid. Given how many people know that many meetings are … Continue reading
Posted in Lean thinking, Management, Quality tools
Tagged Lean thinking, meetings, Quality tools
4 Comments
Quality Conversation with Gary Convis
Quality Conversation with Gary Convis by Norman Bodek: There are two pillars; one is continuous improvement. You might not call this a human issue exactly, but Toyota’s success rests on the need for all employees, all management, to be looking for and striving for continuous improvement and never being satisfied. … We believe very strongly in what the Japanese call “genchi genbutsu,” the foundation of Toyota’s engineering strategy, which means “Go, see, confirm and be aware with your own eyes.” … Continue reading
Lean Accounting: What’s It All About?
Lean Accounting: What’s It All About? [the broken link was removed] by Brian H. Maskell and Bruce L. Baggaley: Companies using Lean Accounting have better information for decision-making, have simple and timely reports that are clearly understood by everyone in the company, they understand the true financial impact of lean changes, they focus the business around the value created for the customers, and Lean Accounting actively drives the lean transformation. This helps the company to grow, to add more value … Continue reading