Lean

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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Use a Gemba Walk to Help You Understand Your Process

A simple, but effective tool to help you better understand a process is a “gemba walk.”  Gemba is a Japanese word for “where the work takes place,” and so a gemba walk is nothing more than taking a walk in the area where the actual work is occurring.  Some of you may remember the term “management by walking around” that was popular many years ago. This is...

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A Successful CI Program Depends on Strong Project Management Fundamentals

I’ve seen it happen more than once where a company starts down the path of Lean, Six Sigma, or Problem Solving to only change course in mid-stream.  It happens for many reasons – lack of resources, underestimating the time required to complete projects, allowing scope creep, project champions and sponsors that don’t ask the right questions, not putting the correct controls in...

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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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How Good Are You As An Organization? How Good Do You Want To Be?

Over the years, much has been written about the pros and cons of lean and Six Sigma.  People often complain about the training costs, the infrastructure required, the teams of green and black belts, and so on, but in my 40+ years of experience nothing has proven to be more successful at getting things improved than a combination of lean and Six Sigma.  I’m not talking about ten, twenty,...

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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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