July 2006 | Gemba Academy

One Definition of Lean Manufacturing

By Jon Miller - July 31st, 2006

During a conference call to plan the agenda for a global meeting of Lean manufacturing leaders at one of our clients, they identified their desire to establish “one definition of Lean manufacturing” at their company. This m

Lean Manufacturing, Chicken Knife. Six Sigma, Cow Knife.

By Jon Miller - July 29th, 2006

I learned a new Chinese expression this week from a Six Sigma Master Black Belt from Taiwan. We were discussing how Lean manufacturing and Six Sigma fit together, and how sometimes there can be misunderstandings and conflicts between t

Error Proof the Pokayoke to Build in Quality

By Jon Miller - July 26th, 2006

In order to have a just in time production system function properly you need to work towards zero defects and build in quality to every process. Otherwise the lack of extra buffer inventory will shut down the material flow when a defec

Getting in the Habit of Change

By Jon Miller - July 24th, 2006

People often say that sustaining the gains of kaizen and Lean manufacturing is the hardest thing. How well you sustain kaizen is really about how well you adapt to change. Kaizen and Lean manufacturing are not “one time and done&

Standard Work is Kaizen Instruction for Managers

By Jon Miller - July 21st, 2006

Standard Work may be the most important Lean manufacturing tool that you don’t know enough about. Built on the three elements of takt time, work sequence, and standard work in process (standard WIP), it is the cornerstone of the

Kaizen Song: g.e.m.b.a

By Jon Miller - July 20th, 2006

g.e.m.b.a. (to the Village People’s “Y.M.C.A.”) Young man, there’s no need to feel down I said, young man, pick your reports off the ground I said, young man, ’cause your boss ripped you a new one There’s no nee

What’s Next After Lean?

By Jon Miller - July 18th, 2006

When I saw the article I thought surely one of the other Lean bloggers would jump all over it. Perhaps it was too easy. So I let it slide for a few days. Then I changed my mind. What’s next after Lean? Asks the interview with aut

Gemba Keiei by Taiichi Ohno, Chapter 28: Wits Don’t Work Until You Feel the Squeeze

By Jon Miller - July 17th, 2006

“When I’m sitting in the board room I have no idea what’s happening on the gemba.” Taiichi Ohno begins, and proceeds to tell the story of what would happen when he was sitting in another office, Production Control. When his eye

Kaizen Secrets of the Toyota Mind

By Jon Miller - July 16th, 2006

There have been many books on the bestseller list with variations on the theme of “how to become a millionaire”. A fellow named T. Harv Eker rolled through Seattle a few years ago and gave a free seminar on the subject. It seemed l

Words of Taiichi Ohno Sensei, Part 3: The Top 8 Pearls of Wisdom on Kaizen

By Jon Miller - July 13th, 2006

Taiichi Ohno loved wordplay. He would take a few choice Japanese words and pack in as much kaizen wisdom as he could. He chose his words carefully, even though in much of his writing he was informal and direct, and not highly articulat

Month: July 2006