Lean by DoingPerhaps hands-on learning is the only way to unlearn ingrained frameworks
Wed, 08/03/2016 - 14:08
Early along, as a student of the Toyota Production System (TPS), now referred to as lean, I struggled with some of the concepts and systems. For example, Shigeo Shingo’s claim that a four-hour machine setup could be reduced to less than 10 minutes… Profitless Part ProliferationA false sense of profitability cloaks great waste
Mon, 07/11/2016 - 13:50
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… Eye of the BeholderThings get ugly fast when we fail to understand lean concepts
Thu, 06/30/2016 - 12:56
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… Traditional Lean?Never forget the people-centric basics of the process
Mon, 06/13/2016 - 12:28
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.… Indefinite PostponementDeath by procrastination
Mon, 05/02/2016 - 14:23
Today’s article is inspired by the politically-charged gobbledygook we call presidential primaries. This battle of principles turned battle of wills reminds me that the role of the change agent can be as much theater as science. In a public forum,… Bump and GrindForcing lean on a fundamentally broken system
Wed, 03/09/2016 - 16:25
Here’s a personal reflection from my distant past that might describe a current state for some of you.
When I began working in manufacturing during the pre-lean era, the quoted lead time for my company’s products averaged 12 to 16 weeks. By the… Ludicrous SpeedWhen it comes to information, fast doesn’t mean lean
Tue, 02/16/2016 - 12:51
Mel Brooks fans will remember Spaceballs, his jocular jibe at the Star Wars franchise. In pursuit of a rebel ship, evil Lord Dark Helmet (played by Rick Moranis) orders his crew to accelerate their craft beyond the speed of light to “ludicrous… Another Use for Duct TapeSolving the true problem behind the problems
Tue, 01/19/2016 - 16:06
This is an article inspired by the glut of recent football weekends. Lou Holtz, the legendary college and pro football coach, offers the following advice to coaches everywhere: “I never learn anything talking. I only learn things when I ask… Seven Mistake-Proofing Mistakes That Promote CynicismWhy <em>poka-yoke</em> isn’t seen as purposeful
Mon, 12/21/2015 - 13:47
A piece of popular lore, provided by Shigeo Shingo, is that the original name for mistake-proofing (poka-yoke) was actually fool-proofing (baka-yoke). Shingo chided managers at Panasonic for using the latter term, as it disrespected workers by … Lazy Lean GuyHonest work needn’t be painful
Mon, 11/23/2015 - 11:23
In 1987, shortly after I became a manufacturing manager, the shop foreman at the time warned me about a young assembler. “Watch out for Michael,” the foreman said. “He tends to bend the rules. You may need to talk to him.”
In fact, I did watch…
