Lean Fav Archives | Gemba Academy

5S and Spring Cleaning

By John Knotts - April 21st, 2023

What better time than now to talk to you about spring cleaning and 5S? Now, you may be wondering what exactly 5S is, and how it relates to spring cleaning. Well, let me explain. 5S is a methodology used in manufacturing and other indus

Constraints Are Opportunities

By Steve Kane - September 28th, 2018

I started my lean journey many years ago while working in the motorcycle industry. I was a parts and accessories manager for a BMW Motorcycles dealership in the Monterey Bay area of California. This dealership had been in business

You Want Me to Do What!?!

By Steve Kane - August 24th, 2018

I coach a variety of teams in diverse industries in the area of continuous improvement. A common struggle is overcoming an obstacle that is often perceived as resistance to change. Improvement is Inherent Change for the better s

Set Full Sail

By Steve Kane - June 22nd, 2018

Getting started with lean in an existing organization challenging on many levels. Often some of the most important steps in a lean journey are not recognized. A common place people think they start is with 5S. It’s an

Where Do I Start with Lean?

By Steve Kane - April 27th, 2018

Where should I start with Lean? is a common question we receive at Gemba Academy. Some say starting with 5S is a must. Others favor eliminating the seven deadly wastes. Others still suggest value stream mapping. A great question

“I Didn’t Teach the Dog Anything”

By Steve Kane - June 23rd, 2017

The Dog is a Handful I have a Jack Russell Terrier named Kirby. Kirby has some–how should I put it–less than desirable behavioral traits. He’s a great dog most of the time. Other times, he can be a handful. Fo

Lean Outside of Manufacturing

By Steve Kane - May 26th, 2017

There are so many examples of lean in manufacturing that it can be easy to understand how well-suited the methodology is for that industry. Folks in other types of organizations and roles often comment that it is difficult to transla

Lean Lessons from Tough Mudder

By Steve Kane - October 21st, 2016

By Steve Kane May 2016 I had the bright idea that I’d register for the Michigan Tough Mudder Mud Run, then find a way to get in shape (ready, fire, aim). I had seen ads and social media posts from finishers and thought t

Create a Learning Path

By Steve Kane - August 19th, 2016

This article is a continuation of the series based on best practices from the Gemba Academy community: Part 1: Don’t let perfect get in the way of good Part 2: Create a Learning Path Lean, for many organizations, involves transfo

Don’t Let Perfection Get In the Way of Progress

By Steve Kane - July 15th, 2016

The Gemba Academy team is in a great position to interact with many lean practitioners around the world. With a thousand or so subscribing organizations and presumably hundreds of thousands of Gemba Academy users, we’re able to see

Safety In Numbers: What Message Are We Sending?

By Steve Kane - June 17th, 2016

Guest contribution by Jamie Parker “Don’t tell the team. I don’t want to be the reason our number goes back to zero.” These are the words a front-line team member shared with her plant manager after sustaining an injury. You se

More Than Metrics

By Steve Kane - March 18th, 2016

By Steve Kane I’ve had some conversations recently about what a successful lean journey looks like. Of course, we talked about key performance indicators and monitoring metrics. As the saying goes, not everything that can be coun

The Only Genuine Knowledge Is That of Actual Experience

By Steve Kane - January 15th, 2016

“The only genuine knowledge is that of actual experience.” ~ Chinese proverb Training is a big part of lean transformation. Countless hours and dollars are spent in training rooms, seminars, and classrooms every year. It’s comm

Happy Winter Solstice

By Steve Kane - December 18th, 2015

By Steve Kane I always enjoy the holiday season. Not only because of the holidays themselves, but also because of the renewed energy I get from ending one year and beginning another. This is the time to reflect on the year that was

5 Thoughts On Dealing With Leadership Resistance

By Steve Kane - November 20th, 2015

By Steve Kane Gemba Academy recently conducted a one-question survey. The question was “What are you struggling with on your continuous improvement journey?” The most common response was related to dealing with leadership resistanc

Improvement Through Personal Fulfillment

By Steve Kane - October 16th, 2015

By Steve Kane Tony Robbins is well known for his motivational speaking, books, interviews and articles. A consistent theme in his work is the six human needs. 1. Certainty: assurance you can avoid pain and gain pleasure 2. Uncertaint

Standard Work Saved a Company

By Steve Kane - September 18th, 2015

By Steve Kane I’ve been an aviation enthusiast most of my life. I started flying sailplanes a couple of years ago and recently transitioned to power planes. The first lesson in flying is an introduction to standard work—specifical

Aerofit Fittings - Courtesy of Aerofit.com

AeroFit’s Factory Improvement Team

By Steve Kane - August 21st, 2015

Chris Ferrier, Manufacturing Engineer with AeroFit, was challenged to increase production on a manufacturing line by one part per hour. While this might sound easy, making it happen isn’t. AeroFit makes fluid fittings for aer

What’s This Thing Called Lean?

By Steve Kane - July 17th, 2015

By Steve Kane My introduction to lean occurred many years ago while working in the motorcycle business. I went to work for a BMW Motorcycles dealer in California as a parts and accessories specialist. My job was to sell cool motor

It’s Not Supposed To Hurt

By Steve Kane - February 10th, 2015

By Steve Kane Getting Started I bought a road bicycle a few years ago for physical fitness. It seemed to be the most enjoyable and least painful form of exercise that I could do from home on a daily basis. Riding, or spinning as cy

One Piece Flow versus Mass Production

By Ron Pereira - February 18th, 2008

Update on Nov 6, 2020: The original version of the video is no longer available. But I did want to add a note that the reaction to this original article was one of the main reasons Gemba Academy exists today. I have left the original c

Value Stream Mapping Overview

By Ron Pereira - February 8th, 2008

One of, if not the single most powerful lean tool available to us is value stream mapping (VSM). The reason it’s so powerful is because of its relevancy. You see, it doesn’t matter if you are an accountant who sits behind a

OEE – Not Just for TPM Programs!

By Ron Pereira - December 20th, 2007

If someone were to force me into a corner and only allow me to use one metric in my plant I would have to choose Overall Equipment Effectiveness (OEE). The reason I would pick it is simple… it is really 3 metrics in one! Here is a qu

Two Types of Kaizen

By Ron Pereira - October 28th, 2007

The word kaizen is fast becoming a buzz word galore. You will hear about how people are “doing kaizen” or running a big “kaizen event” next week. Many times folks are in fact executing kaizen’s in an att

Why Flow Counter Clockwise?

By Ron Pereira - September 30th, 2007

When designing a u-shaped cell it is often recommened that material flow in a counter clockwise direction. Why is this? It’s about the right hand Research shows that most people are right handed. I have heard that as many as 85%

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