Continuous flow is the act of moving a product through the production process from start to finish without stopping. In pure continuous flow, the cycle time equals the lead time, as the product never sits in a queue waiting to be worked on. Contrast this to batch and queue production in which larger groups of parts move as a unit and then wait for an operator to have time to work on them. Continuous flow Read more…
Check Sheets are a means of tallying data. They are generally kept at the point of data collection, and every time a particular incident happens, a check is placed in the appropriate box. In many cases, the check sheet will be broken down into a grid. The columns most often contain the different types of occurrences. The rows are broken down into time periods, whether hours, days, or a longer period. This second axis may Read more…
Lean works. It’s been proven time and time again that its methods and strategies are effective, and that companies that crack the code of Lean improve their operations significantly. But Lean also flounders in some companies, making it harder than it needs to be and limiting its progress. My perception is that there are a few common obstacles that prevent Lean from taking root. Managers don’t seem to share in the burden. When leaders don’t Read more…
In traditional manufacturing, there is a tendency to run large lots, or batches. This occurs for a variety of reasons—large distances between processes, long setup times, or simply poor processes. When the batch is transferred to the downstream process, it sits in line. That is the ‘queuing’ part of batch and queue. Batching and queuing tends to drive up inventory and lead time and creates inefficiency in an operation. It also increases the space needed Read more…
Autonomation is automation with a human touch. It essentially means that an automated machine has the built-in intelligence to identify when there is a problem, shut itself off, and signal the operator. This action prevents the machine from damaging itself or from producing more bad parts. See Also: Jidoka
I recently went to a restaurant, and received this bill for an item that cost $12.95 on the menu: Item Price Food $12.95 Food Preparation Surcharge $3.95 Property Tax Surcharge $0.95 Site Security Fees $0.37 Waiting Area Use Fee $0.46 Clean-up Fee $0.99 Booth Usage Fees $0.76 Imagine how this bill could damage an employee-customer relationship. OK, I jest here, but this is a typical situation for airlines. The fare you see when you purchase Read more…
Learning the technical aspects of Lean takes time and effort. But, what few people recognize is that it is much harder to develop the soft skills of continuous improvement. The following list contains some of the greatest challenges—and opportunities—for many Lean leaders. Granting Authority The single biggest mistake that leaders make in a Lean company is failing to grant authority to their team members. That doesn’t mean giving team members blank checks to do anything Read more…
I was leafing through a folder of interesting articles I clip to give me ideas for my writing, and came across a Men’s Health clip from a few years ago. The story doesn’t provide numbers, but it quotes ‘studies’ that show some of the benefits of being a happy person. You make more money. You are more creative. You live longer. Unfortunately, the article says that 50% of your disposition for happiness comes from your Read more…
Nothing beats hands on practice to reinforce important points in Lean training. Our Lean Lego® exercises do just that, all while making your training fun. Why use Velaction’s Lean Lego exercises? They are fun. What better way engaged people in a training exercise than making them enjoy it? Our Lean Lego exercises are easy to use. We include everything you need in each kit. No running around gathering up components, or printing things out. Plus, Read more…
In my travels, I have lost track of how many people have told me that their situation is unique, or that their process is different. The truth of the matter is that they are right. Every process is unique, and every situation is different. But ironically, that very fact means that they are not. Every person going through a Lean transition faces similar challenges. They have to adjust to change. They have to find a Read more…
I am often asked about what can make implementing Lean easier, or how to do it quicker. Unfortunately, implementing Lean takes a lot of effort. It requires a lot of expertise, experience, and a wide array of skills to make it successful. There are no magic wands, special beans, or secret scrolls passed down from the tribal elders. But there are a few actions that leaders can take that will help start their Lean efforts Read more…
Last night, I was trying to think of a topic for an article to write for this morning’s post. At first, I felt my blood pressure start to rise in lockstep with the rising job stress. But then, I remembered something. I know Lean principles. I suddenly realized that I’ve been following my processes, so I have a log of article ideas ready to go. I looked through them, and saw this topic—how Lean reduces Read more…