Handoffs

Handoffs occur when work is passed from one person to another person. In most cases, a handoff entails reorienting the work and getting it ready to add value to it. Handoffs in manufacturing act a little like speed bumps. They create hiccups in the flow of work. When a handoff Read more…

Errors

Preventing errors is one of the ways Lean helps reduce waste. Before we talk about preventing errors, let’s first talk about what errors are. They are the gap between what happened and what should have happened. Simply put they are mistakes. Errors link to defects. Every defect that is identified Read more…

Conflicts

Conflict is the state of disagreement or opposition. Conflict is a normal part of any Lean effort. When a process is changed, people invariably have differing opinions about the best way to fix things. In some cases, there is even conflict about whether something is even a problem. Conflict is Read more…

Complacency

Complacency is the state of being content with achievements while simultaneously being unaware of the pending dangers. One of the greatest risks successful Lean companies face is complacency. They make massive gains, and become highly competitive in their markets. Then they become complacent and rest on their laurels while the Read more…

Best Practices

The term ‘best practice’ is commonly used to describe a standout process that is the best known way to do something. ‘Best practice’ is really a misnomer. There is no such thing as a ‘best’ practice—only a ‘best known practice’. The term itself goes contrary to the whole premise of Read more…

Flat Surfaces

Flat surfaces are bad for work areas. They collect dirt, dust, debris, etc. They don’t support processes. People use them for storage. Work hard to eliminate flat surfaces in work areas. Flat surfaces collect debris. They collect dust. They collect extra parts, extra tools, extra equipment, extra Work-In-Process (WIP). If Read more…

Safety

Safety is freedom from injury and harm. The most obvious freedom is from immediate bodily injury. Safety switches, gate, guards, etc. help provide this, as does proper training and well-designed processes. Safety also includes freedom from chronic conditions that accumulate over time. This includes things like repetitive stress injuries, and Read more…

Intelligence

Intelligence is one of the many facets of “smartness”. Intelligence is the capacity to learn, but it doesn’t always translate into actually possessing knowledge. Having the capacity to learn does not mean that one has actually learned. Intelligence is a highly valued trait in Lean, as continuous improvement works best Read more…