In Part 1, we discussed the efforts of Lean Manufacturing and the failing results that many American companies experience. The tools work for some but not others, and since they work so extremely well for Toyota, we need to understand what we are doing wrong. We mentioned this article that thoroughly discusses one popular Lean… Read more
The Lean Manufacturing that is popular today originated in Japan with Toyota. The Western civilization has adapted it with measurable success, but for some companies, efforts fall flat. There doesn’t seem to be a rule of thumb as far as what kind of manufacturer or company size is more or less likely to succeed at… Read more
Meet Joe. He’s a respectable, hard-working guy who does his job well. Here you see one of the many things he does every day – push a cart filled with units to get from one place to another. Having a cart makes his job easier, right? He can move more units at a time, and… Read more
The manufacturing industry is aching from a labor shortage that is aggravated by a double-whammy. First, the stellar workforce it has is getting older. Employees can’t physically accomplish what they could a decade or two ago. The jobs are physically demanding, so workers are more vulnerable to injury, and they can’t get things done at… Read more
Separate strategies for making a warehouse greener or leaner often complement each other. After all, they both aim to reduce waste and make the most of the resources you have. Since lean practices show such significant financial benefits, it is often the more commonly sought-out approach when it’s time for a change. Looking at the… Read more
The holidays are upon us, and if you haven’t already beefed up your warehouse staff, you’re about to. The extra help may give you more hands on deck, but seasonal employees also come with some risks. These individuals don’t have the experience or ingrained knowledge that your veteran workers have. This makes them more vulnerable… Read more
Manufacturing has seen some amazing improvements in the last several decades. Tools and equipment make jobs easier and allow more work to be done in less time. These advancements alone, however, do not make manufacturers as successful as possible. Output is not the only factor to measure when you look at overall profit potential. Lean… Read more
Lean manufacturing really is for everyone, but the strategies to choose from don’t work the same for everyone. Smaller sized manufacturing companies can have a tough time choosing the best starting place for Continuous Improvement. The easiest and best first step is 5C. The 5Cs are: Clear Configure Clean & Check Conformity Consensus or Custom… Read more
There is no shortage of resources on lean manufacturing strategies, also known as Kaizen, or Continuous Improvement. These can be overwhelming to sift through and choose from, especially for smaller businesses. Small to medium sized manufacturers have different needs and resources than large ones. Therefore, these companies can have a difficult time deciphering where to… Read more
In our last article, we covered the basic differences between a Gemba Walk and Management By Walking Around. What is most different is the latter takes a structured approach and an intent to identify opportunities to implement lean strategies. One piece of this model is the Gemba Walk Evaluation Sheet. Depending on the manager doing… Read more