There are countless quotes about rules, most of them negative. Rules are made to be broken. –unknown There are no rules here – we’re trying to accomplish something. –Thomas A. Edison Rules and models destroy genius and art. –William Hazlitt The common perception of rules is that they are stifling, Read more…
A rule of thumb is simply a general process applied to a broad condition. They tend to have a wide-ranging application and are more based on accumulated experience and tribal knowledge than actual science. This is different from rules, regulations, Standard Work, and other forms of documented instructions. In those Read more…
The red tag system is simply a communication tool used to identify items that a person has flagged for removal from a work area. While the tagging is most frequently done during kaizen events, it can be done at any time. In a nutshell, when a person finds an item Read more…
Spend any time around Lean, or any other continuous improvement methodology, for that matter, and you will undoubtedly hear the term “Respect for People.” It is a simple concept that should act as a moral compass in how people do business. The fact is that a company does not have Read more…
Rework is the act of correcting a defect. Rework is obviously waste, and can be avoided by eliminating the root cause of the problem. The further downstream rework is done from where the error originally occurred, the more the problem costs to correct. Rework is most commonly initiated after an Read more…
Risk management is the process of identifying risks, reducing them when possible, and making plans to deal with undesirable outcomes. Risk management can be done for an ongoing concern, such as a product line or company, or for an individual project, such as rolling out a new software package. Risk 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…
Results are the outcomes or consequences of actions. In the continuous improvement world, results are most commonly viewed as the intended outcomes of an operation, organization, process, or project. This is in contrast to unintended side effects of a process. Actual results are compared to goals to indicate how effective Read more…
Random means occurring by chance. There are formal mathematical definitions regarding probability distributions, but the basic definition is how the typical non-mathematician looks at randomness. But even with that simple definition, we often think of things as being random when they really are not. In truth, even something as simple Read more…
Repeatability is the ability for the same individual or team to get identical results from a process time after time. Essentially, repeatability is the opposite of output variation. When processes are not repeatable, the problem falls into three basic categories. A variation in inputs causes poor repeatability. A poor process Read more…
A reaction plan is the series of steps that you would take in response to a specified abnormal condition. A reaction plan helps to minimize damage. It reduces the time between the occurrence of a problem and a stopgap. While a reaction plan is important, there is one big shortcoming. Read more…
It takes a lot of discipline to make sure you do a root cause analysis on problems rather than leaping to conclusions about what is going on. The definition of a root cause analysis is simply the act of going through a systematic process to identify the source of a Read more…