Complexity is the state of having many interconnected parts. It is anything that has a lot of intricacy to it. The word has a negative connotation to it in Lean. So, what is excessive complexity from a Lean perspective? It is adding more to a process than is needed. It Read more…
When we think of process improvement, our minds often jump immediately to what the business is doing to fill a customer’s needs. We are not as good at looking at the steps the user takes. Is customer value added every time the product is used? A case in point. I Read more…
A line shift is a synchronized movement of all the production work on an assembly line. It can be done in several ways. Manually, in which each person pushes their work to the next station on a signal. On an indexed moving line, in which the line moves and then 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…
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…
Absences are, in a nutshell, times when a person is not present to do their normal work. Absences primarily fall into two categories from a production viewpoint—planned and unplanned. Your company’s HR team may categorize absences in a larger variety of ways, but from the operations standpoint, human resource definitions Read more…
“Bells and Whistles” are the extras on a product…or on a process. On a product, bells and whistles are the features that enhance the product, but don’t significantly change the function. Years ago, power windows were part of the bells and whistles packages that carmakers used to distinguish cars from Read more…
Repetition is the act of doing something the same way over and over again. Repetition helps provide stable outputs to a process by making the inputs consistent. Repetition has a side effect of creating muscle memory—the state where your body acts without conscious thought, much like walking. You don’t have Read more…
Process improvement is the act of reviewing a specific process to make it Process improvement is the act of reviewing a specific process to make it better. The degree of formality can be minimal, such as an immediate decision to change a method on the fly. This might include moving Read more…
A kanban is a signal that gives an instruction to get, move, produce, order, or take some other activity with production materials. Its literal translation from the original Japanese term, though, is “signboard” or “billboard”. Kanbans tell you when to order, what to order, how much to order, and where Read more…