Visit CI Central | Visit Our Continuous Improvement Store

Gotta Go Lean Blog

Visual Control

A visual control builds on 5S. It uses organization and standardization to make an abnormal condition stand out. In a Lean environment it does three things: A visual control shows the current condition quickly. A visual control shows what the standard is quickly. A visual control links to an action. Simply put, visual controls helps Lean companies make quick, pre-planned decisions without guesswork. As an example…A visual control is often used to highlight an abnormal Read more…

By Jeff Hajek, ago

Pull System

A pull system (or pull production) is one in which items are only made, transferred, shifted, withdrawn, etc., when there is demand from a downstream customer. This sharply contrasts from a push system in which the downstream actions have no impact on what the upstream process is producing. Pull systems and one-piece flow combine to form JIT production. Pull says only build with demand. Flow says use the smallest quantity possible, and shift in small Read more…

By Jeff Hajek, ago

Upstream Processes

Lean often uses the analogy of running water. Making products move quickly and effortlessly is described as flow. Flow is often likened to straightening out a meandering river into a smooth, straight channel. The processes that get those products and services to the customer are known as the value stream. “Upstream” takes that analogy further. The term describes internal supplier processes, or those closer to the beginning of the value stream. Downstream processes are the Read more…

By Jeff Hajek, ago

Downstream

Lean makes extensive use of the term flow. As a result, one of the most common teaching analogies Lean practitioners use is that of a meandering river being slowly but surely turned into a deep, straight, fast moving channel. That flow starts at the supplier and finishes at the customer. As a result, downstream refers to any movement in the direction of the customer. Keep in mind that information often flows upstream while products and Read more…

By Jeff Hajek, ago

Value Stream Map

A value stream map (VSM) is a drawing that depicts the flow of material and information along a value stream. A value stream is the linked series of processes that brings a product from raw materials into the hands of the customer, or that provide a service to a customer. This map is generally hand drawn, as it lets the mapper record information on the spot. For that reason, it often looks a little scruffy Read more…

By Jeff Hajek, ago

Current State Value Stream Map

The current state value stream map provides a 30,000-foot snapshot of how an organization operates. One of the unique aspects of this tool compared to others is that it shows the flow of both materials and information. This tool is extremely useful for a few reasons: It provides eye-opening insight into the level of waste in an organization. It provides a foundation upon which to build a plan to improve. It acts as a communication Read more…

By Jeff Hajek, ago

TPS

TPS is the acronym for the Toyota Production System. TPS is more of a business philosophy than a production system, though. It focuses on manufacturing and logistics but doesn’t neglect the human aspect of production. TPS was founded in large part by Taiichi Ohno. TPS can trace its origins back to the early days of Ford and American supermarkets. Mr. Ohno was impressed with the way supermarkets ordered their inventory. He combined it with the Read more…

By Jeff Hajek, ago