A push system is one in which an upstream process sends work to a downstream process prior to the downstream process requesting it. Batch and queue systems in which large lots are sent to the next workstation to wait in line are push systems. Generally Lean systems attempt to move towards pull systems, in which no work can move without a request. The basic problem with push systems is that they are disconnected from the Read more…
A standard is a rule or principle that sets a minimum level of acceptable behavior. It is also something to which other things may be compared, such as a breed standard to evaluate dogs, or a measurement standard used to certify meters and testing devices. Standards in business are useful because they take ambiguity out of requirements. Unfortunately, when used inappropriately, they can also take creativity and initiative out of a workforce. Standards come in Read more…
A few weeks back, Tim McMahon and I hosted an online show in which we talked about how a pair of coffee makers can be a great backdrop for Lean lessons. They provide simple examples and are familiar to most people. They also have the advantage of not tuning people out. When business world examples are used, people routinely disregard parts of the lessons. They believe that their work area is different, so the lessons Read more…
The average or arithmetic mean (commonly just called the mean) is one of the most common measures of central tendency of a set of data. In layman’s terms, a measure of central tendency is simply a way of trying to describe the middle value of a set of data. The arithmetic mean is calculated by dividing the sum of the elements in the sample by the number of elements. The following formula is used to Read more…
I saw an interesting report yesterday about a passenger in San Diego who videotaped an interaction with some TSA employees. Reportedly, the passenger opted out of the backscatter screening, but then threatened to have the screener arrested if he “touched his junk.” Now, I’m not going to get into the details about this incident. Instead, I would like to address the bigger picture. This most recent report was about the intrusiveness of searches and infringement Read more…
I heard an interesting comment about Standard Work the other day. A reader asked why someone just didn’t create a Standard Work document on writing a symphony so anyone could be a composer. It’s always hard to tell someone’s meaning on a short comment like that. It could be taken as an endorsement of the power of Standard Work, or it could be a sarcastic critique on how Standard Work removes creativity from the workplace. Read more…
Facility layouts come in three basic flavors. Unplanned Layouts. Some facilities are not arranged by any master plan. As new machines are needed, they are placed where they will fit. It is fairly uncommon for this method to be used throughout an organization, but many will have a few machines that are obviously placed where there was space. Functional Layouts / Process-Oriented Layouts. This layout style is characterized by groupings of similar processes that serve Read more…
In statistical terms, the law of large numbers is a theorem that postulates that as the size of the sample of a random variable increases, its average will approach the theoretical average. In layman’s terms, the law of large numbers simply says that over time, the more times you roll a dice, the more likely the average of the rolls will turn out to be 3.5. If your sample size is one, meaning a single Read more…
Investments trade current resources for future gains. The most common forms of investment include: Financial holdings designed to provide a return on investment (ROI) in the form of appreciation, dividends, or interest. Physical holdings intended to appreciate or generate income, such as real estate Physical items used to create other products or provide services, such as software systems or CNC machines The other big form of investment is in people. A workforce doesn’t become great Read more…
Leadership is a critical component of Lean. Whether you are at the top of a company leading the Lean charge, or an engineer working to guide a group of operators on their Lean journey, you need a variety of leadership skills. But while the specific tools you use to lead in the different roles may vary, the underlying principles are the same. So what are the leadership principles that link to success in Lean organizations? Read more…
The Hawthorne Effect originated from experiments at the Hawthorne Works, owned by Western Electric, in Cicero, Illinois in the first half of the 1900’s. While there were a variety of experiments, the most commonly referenced study was about illumination. Researchers conducted a series of experiments to identify the optimal lighting levels in the workplace. Initial findings showed that increasing lighting levels resulted in productivity increases. The effects, however, were short-lived. Continued experiments showed that whenever Read more…