Category: Methods and Tools

I was talking recently with a very smart distribution manager at one of my clients.  We’ve been very involved with Workplace Organization and Visual Management all over the organization and especially in manufacturing.  That fits my usual modus operandi.

The manager was telling me that his folks are getting a bit bored with these phases and are starting to wonder what the purpose of all this “lean stuff” is given that a strong focus on Workplace Organization doesn’t do much for them in the warehouse.

Continue reading ““But What If We Don’t Need Workplace Organization?””

In the last post, we recommended posting charts at each work station to gather information about production and performance that would be used to identify and solve problems.  Remember, the purpose of these charts isn’t simply to gather data that will be used later by your resident black belt (though it certainly could be).  The purpose is to identify and address problems in real time, in other words, lean problem solving.  So we’re interested in gathering as little information as possible in as “user-friendly” a way as we can and still get good problem solving accomplished.

Continue reading “How to Implement Lean Manufacturing: Simplify and Solve – Value Stream Mapping and Team Problem Solving: Part 10”

Lean efforts will be successful to the degree to which we have operational excellence in the shop.  Inventories and costs will decrease to the extent that we can reduce downtime, scrap, delays, scheduling problems, die problems, and equipment problems.  There’s no value in a value stream mapping and no good in pushing a pull system unless we also address those problems that will keep them from being effective.  Supervisors and operators need to be actively involved in problem solving.

Continue reading “How to Implement Lean Manufacturing: Simplify and Solve – Value Stream Mapping and Team Problem Solving: Part 9”

I’ve updated a video I posted to YouTube some time ago.  (Actually, what I did was delete the old video and replace it.)  The video is a quick overview that answers the question, “What is 5S?”.  I hope you’ll take a look at it.

Over the years, I’ve helped a number of clients with process mapping exercises.  Now, process mapping is one of those things you can read about and look up on the interweb and still not get much help when it comes to actually doing it with a team.  (That said, a good book on the topic is “Improving Performance: How to Manage the White Space on the Organization Chart” by Geary Rummler. )  I’ve learned some things that can help you.

Continue reading “Process Mapping: Lessons I’ve Learned”