Sensors are mechanical devices that are sensitive to their environment, and that communicate information about what they detect. Sensors can detect pressure, temperature, speed, and a host of other things. Sensors are commonly linked to either an alarm of some sort (a buzzer when a seat belt is not fastened), Read more…
A manufacturing fixture holds parts during the manufacturing process. Fixtures come in a wide range of types. In their simplest form, they may be a series of pins sticking up from a flat surface to keep a part from sliding. They can also be much more complicated, with a series Read more…
The standard work process is a critical piece in the implementation of Lean manufacturing programs. It helps to stabilize a process and it provides a basis for continuous improvement. No matter how good something is, though, there is always a cost to it. For standard work, the price can come Read more…
Many years ago, when I was a lieutenant in the Army, I was responsible for a motor pool—a military word for a glorified lot where the unit parked its forty trucks when they weren’t in use. Every Friday afternoon, my sergeants and I managed the cleanup of the motor pool. Read more…
To understand problem solving, one must first have a clear definition of what a problem actually is. A problem is simply a gap between an expectation and reality. The most common way people look at this relationship is that they focus on a change in performance, meaning that the reality Read more…
Evidence is the data that supports a theory. It is what separates opinion from fact. Lean relies heavily on problem solving to make improvements. In order to get to the root cause of a problem, people in Lean companies must act like detectives, uncovering evidence to understand processes better. Evidence Read more…
On the job emotions are rarely talked about. But let’s begin with emotion in general. Emotion is something that we are all familiar with. It is the internal reaction we have to things- the shriek when you win the lottery, the gasp at bad news, and the anger when someone Read more…
8D Analysis is a problem-solving methodology. It takes a step by step approach to identify the root cause of a problem and permanently eliminate it. Because there is a cost in terms of time and effort in using a formal methodology such as 8D analysis, it is usually only done Read more…
The scientific method is one of many problem solving techniques. There are 5 basic steps to the scientific method. Observation: Gather facts and data about a situation. Form a hypothesis: In this step of the scientific method, the user makes a statement about what is happening and why. In effect, Read more…
Great Lean practitioners and change agents know the same thing about implementing kaizen that a carpenter does about his trade. You have to use the right tool for the right job. When building cabinets, a woodworker relies on tools other than his hammer. Lean companies should look to tools other Read more…
When Lean starts in an organization, it is normally emphasized in production areas, typically the shop floor and then customer-facing administrative areas. As those areas improve, the form and level of help they receive from the supporting functions can lag. The Lean organizations can feel trapped. Unlike the relationship with Read more…
Discussions about continuous improvement frequently mention the term ‘waste’ which is anything that doesn’t add value. But how often are the seven wastes in Lean discussed with respect to managing teams? Leadership, like operations or any other process, uses resources. Doesn’t it make sense to figure out ways to lead Read more…