Kaizen

Standardize Work Process To Provide Customers Better Products & Services

Much of the work we do consists of repetitive tasks:  changing a die in a stamping press, closing the books every month or running a weekly or monthly meeting.  These repetitive tasks can be studied and improved to make them more efficient, reliable, easier, safer, and more productive.  We  then document the best method and teach it to everyone associated with the task.  This will make...

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Ten Steps To Analyze And Improve A Product Or Service Using A Value Stream Map

Many processes suffer from inefficiency, mistakes, errors, defects, downtime and late delivery due to the waste inherent in them.  The waste I’m referring to are: Transportation Inventory Motion Waiting Over-processing Over-production Defects Safety These waste exists because most of the time it’s the way the process has always been done and no one questions it or looks for the...

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Striving For Perfection Is The Essence Of Lean Thinking!

Perfection in lean terms means the total elimination of waste in an enterprise so that all activities in a value stream create value.  What makes striving for perfection so difficult for most of us is that we live and work in the short term whereas perfection only seems plausible in the long term. There are two paths to perfection, an incremental path, kaizen, and a radical path, kaikaku....

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Is Too Much Motion Tiring You Out?

  Masaaki Imai in his book, Gemba Kaizen, A Commonsense, Low-Cost Approach to Management, states that any motion of a person’s body not directly related to adding value is unproductive.  Some examples of motion waste include: Searching for jigs, fixtures, tools, files, etc. Bending to lift heavy loads Turning to retrieve or dispose of products Reaching for components and...

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How Variation In Work Environment Can Affect Productivity and Create Problems

We seldom think of our environment as being a detriment to our job.  But work environment can have a larger affect on your productivity and can create problems that lead to errors, defects, and costly rework. Mother nature and environment can have a dramatic effect on the products we produce and the services we provide. Some of the obvious factors include humidity, excessive heat, cleanliness,...

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Material Issues Create Huge Losses!

Material problems wreak havoc in many operations.  Inconsistencies and variation within a lot or between lots of material can cause operators to constantly tweak machines and processes, which in turn can lead to defects and high scrap rates. Having multiple suppliers for the same material creates variability and can cause production delays, especially if the change from one supplier to another...

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