Efficiency

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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New Ideas, Experimentation and Faster Change Must Be The New Norm

We’ve all heard the adage, “If you’re not changing, you’re standing still and falling behind!” many times in the last 15 years.  But I think it is even more appropriate today in the fast paced world we live in.  Look around and you’ll see companies that were thriving a few short years ago are now struggling just to keep the doors open.  Why is that? I think...

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Don’t Let Luck be the Major Factor in How You Define and Transfer Critical Process Knowledge

One of the largest contributors to inconsistency or variability in an organization is caused by lack of a written method, i.e., a procedure, work instruction, or standard work.  When no documented method exists, knowledge of a particular job is based on tribal information and most workers have their own way of doing the work.  Often their is a lack of an effective method for defining what is...

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