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Gotta Go Lean Blog

Asynchronous Learning

Asynchronous Learning

Asynchronous learning is the concept of teaching the same material to students at different times or places. It is also referred to as location independent learning. The format of this material can vary. It is commonly recorded video or audio programs but can be virtually any medium. Asynchronous learning does not imply independent learning. Students communicate about the material after absorbing it. This discussion can be done via forums, and teachers may actually require a Read more…

By Jeff Hajek, ago

What industries or types of companies benefit most from Lean?

What industries or types of companies benefit most from Lean? Lean is often thought of as being specifically for manufacturing. There is some truth to this if you think of Lean as a set of tools. Many of the tools are geared towards manufacturing. Kanban cards, SMED (Single Minute Exchange of Dies), 5S, Standard Work, and takt time are all tools that do work best when there is a high volume, low variation product line. Read more…

By Jeff Hajek, ago
Build a Lean Infrastructure

Build a Lean Infrastructure

Success at continuous improvement requires having a Lean infrastructure in place. This comes in two basic forms. There is the traditional view of infrastructure—the physical systems that support an operation. There is also the intellectual Lean infrastructure. This is the collection of knowledge, tools, documents, training materials, and the like that support continuous improvement efforts. Physical Lean Infrastructure Your Lean infrastructure should support the types of tasks you’ll need to do at the rate you’ll Read more…

By Jeff Hajek, ago

Success Factors When Starting A Continuous Improvement Journey

There is a pretty high failure rate with Lean. I’ve seen studies that said 76% of continuous improvement efforts under deliver, and I’ve heard anecdotal stories from Lean bloggers that claim upwards of 90% of implementations fail. The truth is that it is hard to pin down precise numbers, as the people vested in studying Lean are also the people that want it to do well. Knowing that the failure rate is rather high means Read more…

By Jeff Hajek, ago
continuous improvement success factors
warning sign

Warning Signs When Starting A Continuous Improvement Journey

Most seasoned consultants look for warning signs when they try to help a company that is early on its continuous improvement journey. Creating a continuous improvement culture is extremely challenging. In its infancy, it is hard to build momentum, and easy to get derailed. Some of the ‘tells’ of a company that is not likely to be successful at continuous improvement include the following: Senior leaders are not engaged If the top brass continually misses Read more…

By Jeff Hajek, ago

6 Big Losses of OEE

There are 6 big losses of OEE (Overall Equipment Effectiveness). 6 Big Losses Breakdowns Setup and Minor Adjustment Idling and Minor Stoppages Reduced Speed Defects and Rework Startup Loss Each of these losses saps a small portion of potential production you could be getting from your machines. Total productive maintenance is the tool used in Lean to deal with these losses. Of note, there are a few different versions of the 6 big losses. Make Read more…

By Jeff Hajek, ago
6 Big Losses for OEE
Y=f(X)

Y=f(X)

Most processes are governed by a basic transfer function, Y=f(x). It is pronounced “y equals f of x.” Y is the output, or “dependent variable”. X is the input (or inputs). Essentially, there are some input parameters that affect the output. When you change one of the input variables, you get a predictable change to the output variable (assuming all other factors remain equal). As an example, paint drying time might be a function of Read more…

By Jeff Hajek, ago

Tolerance Stackup

Tolerance stackup is the cumulative effect of the components of a product being skewed towards the same side of the specification limits. Tolerance is the range between the lower specification limit and the upper limit of a part. Imagine you have a product that lines three or four or more components up end to end. Each will have some sort of distribution and when you combine the distributions of all the parts, by something called Read more…

By Jeff Hajek, ago
Tolerance Stackup
error proofing server bank

Error Proofing

Error proofing, also referred to as mistake proofing or poka yoke, is the art of building processes that make it nearly impossible to make a specific mistake. Error proofing is targeted at specific errors—they are not general in nature. This concept is predicated upon the concept that errors cause defects. To remove defects from your products or services, you must first identify the process step where the error is occurring and eliminate the possibility of Read more…

By Jeff Hajek, ago

Nominal Data

Nominal data is a type of qualitative data. It contains a set of possible values that has no measurable sequence to them. For example, “favorite pet” would be nominal data set. The values might include dog, cat, snake, frog, and horse. While most people would agree that dogs rank much higher than cats, for the purpose of data analysis, there is not an inherent sequence to these values. Nominal data is the most basic form Read more…

By Jeff Hajek, ago
Nominal Data

DPMO

DPMO is the abbreviation for defects per million opportunities. It is a metric commonly used in six sigma. Presumably, if you are engaged in an active process improvement effort, you will have made (or will eventually) make significant improvements to your quality. For that reason, it can be difficult to conceptualize small decimals, like .003 or .00045. It is easier for most people to compare 3000 to 450. To calculate DPMO, divide the number of Read more…

By Jeff Hajek, ago

Kaizen Problem Statement

On our Kaizen Charter, we devote quite a bit of space at the top of the form to the problem statement. This should be a good indicator as to the importance we place on it. A good kaizen problem statement serves two main purposes. The first is that it creates clarity and focus on the project. Making sure that everyone is in agreement on what the issue is goes a long way towards developing a Read more…

By Jeff Hajek, ago
Kaizen Problem Statement