Efficiency

Transportation Waste Can Create A Huge Burden For Organizations

Transportation is a common source of waste in many companies and includes the excessive and unnecessary movement of materials, products, information and paperwork and often exists where there is disorganization or a lack of clear procedures. Some specific factors that can trigger you to look for transportation waste are: Multiple operational locations where companies split operations among...

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Machine & Equipment Issues Create All Kinds Of Waste!

Is your operation plagued with equipment issues that drive you crazy? Old, outdated, hard to maintain, constantly down, or making bad parts — equipment exhibiting these conditions can really drive a plant manager to drink! Or maybe it’s an office copier that keeps jamming up or a computer system that has a mind of its own and decides to go down or won’t boot...

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How a Lonely $25 Grease Gun Contributed to a $1Million Problem!

Many of us go to work each day, do our thing, and feel pretty good that we gave our organization a good days work.  But how many of us go to work each day and really think about how we can cut cost and save our organization time and money.  We’re all running around trying to get things done and never have time to think about how we can improve the process.  The following is a true story...

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Don’t Let Excessive Motion Sabotage Your Operation

A simple, but effective tool to help you eliminate waste due to motion is the spaghetti diagram.  You start by getting a layout of the area or by drawing a simple sketch.  The idea is to observe an employee perform a task and document all the movement the employee makes in performing that task.  Figure 1 is a spaghetti of a change over process on a machine.  As you can see there is a lot of...

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Mapping Business Processes Isn’t That Difficult

  Process mapping is a very useful tool that not only helps you document your current process but can also serve as a framework for making processes more consistent and efficient. Just last week, I had the opportunity to lead a group of 23 HR professionals and develop a process map for their on-boarding for new hires.  All were from the same company, but represented about eight locations...

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Five Green Belt Projects Rock with a Combined Yearly Savings of $743,000!

Last fall I had the opportunity to conduct a Lean Six Sigma training class at Kent State University, Trumbull Branch.  The training concentrates on teaching the participants how to identify and eliminate waste using the various lean techniques and how to reduce process variation by concentrating on the 6M’s (Man, Machine, Material, Method, Measurement, and Mother Nature).  Participants...

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