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William A. Levinson
Masaaki Imai, author of Gemba Kaizen (McGraw-Hill Education, 1997), introduced the concept of the value-adding “bang,” the exact moment at which a process adds value for the customer. He meant the moment at which an official stamped a document, but the same concept applies when a stamping or…
Mark Graban
Given all of the problems that exist in our American healthcare system, it’s encouraging that most healthcare organizations are endorsing or practicing some form of process improvement or operational excellence strategy. Under the banner of different labels and using different combinations of…
Harish Jose
There is a concept in lean known as a “monument.” It refers to a large machine, piece of equipment, or something similar that can’t be changed right away, and so you have to plan your processes around it. This generally impedes the flow and frequently becomes a hindrance to lean initiatives. A…
Bruce Hamilton
I wrote a piece a little more than five years ago about a variety reduction program (VRP), an amazing but little-known product-design optimization tool. At the time I referred to VRP as an idea whose “time had not yet come.” Last week, as I gave a short presentation on VRP, I realized that five…
Bruce Hamilton
Many moons ago, when I was just getting started on my lean journey, I visited a large automotive supplier to benchmark pull systems. My own factory had started a pilot kanban between two work centers and I was hoping to gain some insight from a more experienced source.
To my disappointment, when…
Ken Voytek
In a recent post, I examined the differences in productivity across small and large manufacturing firms, and noted that there were differences across manufacturers in terms of size. But it’s also clear from the literature that productivity differs across companies even in the same industry.
Why…
Pacific Northwest National Laboratory
An improved titanium alloy—stronger than any commercial titanium alloy currently on the market—gets its strength from the novel way atoms are arranged to form a special nanostructure. For the first time, researchers have been able to see this alignment and then manipulate it to make the strongest…
Steve Melito
How competitive is American manufacturing? By the year 2020, the United States is projected to take the top spot in the Global Manufacturing Competitiveness Index (GMCI), a multiyear research platform from Deloitte and the Council on Competitiveness.
The 2016 GMCI surveyed more than 500 of the…
Fred Schenkelberg
A fault tree analysis (FTA) is a logical, graphical diagram that starts with an unwanted, undesirable, or anomalous state of a system. The diagram then lays out the many possible faults, and combinations of faults, within the subsystems, components, assemblies, software, and parts comprising the…
Howard Sklamberg
Globalization is posing challenges for public health. For the U.S. Food and Drug Administration (FDA), part of that challenge is the ever-increasing volume and complexity of FDA-regulated products coming to America’s shores.
In fiscal year 2015, there were more than 34 million shipments of FDA-…
Ryan E. Day
Sponsored Content
In the most basic terms of engine exhaust theory, more flow equates to more performance. The aim is to improve the efficiency of your vehicle’s engine, boost performance, and save money on fuel. Auto-jet Muffler Corp. has implemented that “improved flow = improved performance”…
Jason Furness
Here’s a “tales from the real world” extract from our book, Manufacturing Money (Amazon Digital, 2015). It offers an example of the “five focusing steps” to improvement, with a particular focus on step one, identify the constraint; and step two, maximize the constraints output.
This was a time…
Harish Jose
In this article I want to look at the concept of equifinality in relation to the plan-do-check-act (PDCA) cycle. In systems theory, equifinality is defined as reaching the same end, no matter what the starting point was. This is applicable only in an open system, one that interacts with its…
Bruce Hamilton
Twice in the last month I’ve heard the phrase “traditional lean” used in public presentations. In neither case did the presenter explain the expression, but one displayed a slide with a Venn diagram showing the overlap between lean and Six Sigma.
I suppose this means that he defined traditional…
Fred Schenkelberg
When products were crafted one at a time, the design and manufacturing processes were often done by the same person. For example, a craftsman would design and build a chest of drawers or a carriage. Some trades would employ apprentices to learn the craft, which also included design.
Larger…
Mike Beels
It’s amazing that, in this day and age, some manufacturers have not yet heard of “lean.” How are they surviving in today’s competitive market without it? The issue is that, in many ways, the customer sets pricing. If manufacturers want to be profitable, they must find ways to become more efficient…
Evan Miller
Sponsored Content
PLZ Aeroscience is North America’s largest custom aerosol manufacturer and packager. It produces its own private-brand products and custom formulations, and provides contract filling for other customers. PLZ has been in business for more than 100 years and during the last six…
Takehiko Harada
Editor’s note: This is an excerpt from the book, Management Lessons From Taiichi Ohno: What Every Leader Can Learn From the Man who Invented the Toyota Production System, by Takehiko Harada (McGraw-Hill Education, 2015).
The phrase, “kaizen equals getting closer to the final process” was hardly…
William A. Levinson
Colonel Paul M. A. Linebarger’s authoritative Psychological Warfare (Infantry Journal Press, 1948) defines propaganda as any planned communication with the purpose to influence behavior, but this definition is actually too narrow. Propaganda consists of any action or communication, whether…
Gwendolyn Galsworth
Visual scheduling is a plain, two-dimensional format that maps out which products, parts, or subassemblies need to be produced, and when, in what quantity, and in what order. Nothing could be simpler.
In companies where schedules aren't published in a single, centralized location for all to see…
Jim Benson
We are all cursed with “surprises” at work. We come in, sit down, get ready for the day. We select a task to start on, and about halfway through, it explodes on us. The seemingly simple task now has 30 subtasks all lined up, ready to destroy our day.
This is stressful. Since we’re likely already…
Mike Micklewright
Quiz time: What significance does the yin and the yang have in discussing standardized training? I suggest that you pause and guess (and then read on for the answer).
OK, we all get it, standards are a part of our lives in the business world, and they are gaining more and more focus as companies…
Tonianne DeMaria
“It is a common experience that a problem difficult at night is resolved in the morning after the committee of sleep has worked on it.” —John Steinbeck
In Personal Kanban (Modus Cooperandi Press, 2011), Jim Benson and I discuss how workflow should be optimized for throughput, not capacity. Work…
Harish Jose
Today I’d like to talk about kaizen—specifically, the order for kaizen. The term has come to mean “continuous improvement,” but kaizen originally translates from Japanese as “change for better.” To help clarify this useful concept, I’ll present three different views for approaching kaizen: Taiichi…
Lawrence Yu
If we used a time machine to transport a pharmaceutical scientist from the 1960s into a current pharmaceutical production plant, it might be surprising to learn that he would already be familiar with most of the processes and production techniques being used. That’s because not much has changed in…
