Lean Manufacturing Archives | Page 19 of 24

Chrysler’s (Lean?) Six Sigma Future

By Jon Miller - August 5th, 2007

The Chrysler Corporation has a new CEO, Bob Nardelli. Nardelli Picked to Run Chrysler in Industry Shift, the August 6th, Wall Street Journal reports. Mr. Nardelli was most recently in the news for bringing a controversial combativeness

Why Is Your Lean Effort Failing?

By Jon Miller - July 29th, 2007

The Lean Blog is always a good place for insights and discussion on why Lean efforts struggle or fail. Previous discussions have delved into Lean efforts that are in fact LAME. Mark Graban wrote about the survey format of the Lean Inst

A Closed Mitt and an Open Mind

By Jon Miller - July 26th, 2007

Sorting through old documents as part of my regular 5S at the office I came across another consulting firm’s Lean training materials, collected about a decade ago. These explained Lean manufacturing and the idea of eliminating wa

10 Common Misconceptions About Lean Manufacturing

By Jon Miller - June 24th, 2007

1. Lean production = volume production. In Taiichi Ohno’s Workplace Management he suggested that the Toyota system was ideally suited for low volume production, and not as well suited for the higher volume production that Toyota

Lean in Japan, Or Not

By Jon Miller - May 30th, 2007

The YouTube video titled Lean in Japan is a bit bizarre. It’s probably strange enough to most people as a window into modern Japan, but overlaid with Lean lingo it’s just weird. It’s not clear if this video is tongue-

Lean Manufacturing by the Numbers

By Jon Miller - May 17th, 2007

Lean manufacturing by the numbers: Zero inventory Zero defects Zero accidents 1 piece flow 1 point lesson 2 bin system 2 point control (AB control, full work control) 3D (dirty, dangerous, difficult) 3 don’ts of assembly 3 don’ts o

5S Challenge: Which S Is Most Difficult and Why?

By Jon Miller - May 12th, 2007

“Which of the 5S is most difficult?” I received this question during a class I was teaching recently. I’ve never been asked this before. People often say “self-discipline is the most difficult” or “s

Lean Sourcing: The Top Three

By Jon Miller - April 25th, 2007

We’re writing today as part of a score of bloggers on the topic of The Top Three issues in sourcing. Here’s is our Top Three: 3. Slow is the New Fast When faced with the hard way and the easy way, always take the hard way. This is

Theme Blogging Week: Lean Sourcing

By Jon Miller - April 24th, 2007

The Sourcing Innovation blog has organized a group of fellow bloggers in a series of posts on the topic of sourcing over the next week. Each of our 20 or so blogs will raise their Top Three issues in sourcing. What can a kaizen blog of

Is Zero Defects Possible?

By Jon Miller - April 1st, 2007

Sonu asked: “Is zero defects possible? If so, what are the steps. We are dealing with around 300 parameters each having minimum 25 to 30 parameters to be met. We find it difficult to maintain zero defect for all parameters. Any t

Why So Much Confusion About Kanban?

By Jon Miller - March 28th, 2007

I had a very interesting conversation today with a friend who is a manager spearheading a Lean effort at a local facotry. His latest focus is on connecting the metal forming operations with the assembly operations using kanban. He obse

Twelve Reasons to Tell Customers About Your Lean Manufacturing Efforts

By Jon Miller - March 24th, 2007

Here is a follow up to reason #3 from of the post Here are 4.5 Signs that Your Lean May be L.A.M.E. from earlier this week. I could think of 12 reasons to tell customers about your Lean manufacturing efforts. 1. Customer behavior is th

Here are 4.5 Signs that Your Lean May be L.A.M.E.

By Jon Miller - March 22nd, 2007

Mark Graban at the Lean Blog coined L.A.M.E. as “Lean As Misguidedly Executed” and Kevin Meyer at the Evolving Excellence blog builds on this idea in pointing out how Lean is often added on in press releases, though it may

Safety Glasses Are a Sign of Unsafe Processes

By Jon Miller - March 20th, 2007

I left the training room too eager to go to gemba today and forgot to put on my safety glasses. Within two minutes one of the safety coordinators on the shop floor stopped me and sent me back to get them. Kudos to the management of thi

Reading Lean for Dummies

By Jon Miller - March 17th, 2007

I just finished reading Lean for Dummies. It covers a lot of ground in 362 pages. It’s full of diagrams, lists and other useful visuals. It is light and accessible reading. Parts IV “The Lean Enterprise” and Part V &#

Lean for People of Average Intelligence

By Jon Miller - March 12th, 2007

When do you know a management concept has hit the mainstream? Like a bug to a windshield, “Lean” as a management approach has now hit bookshelves in the form of Lean for Dummies. It set me off on a minor rant in the office

The 5 Why Questions, Like All Roads, Lead to Rome

By Jon Miller - March 7th, 2007

Today Patrick Shumaker from Gemba forwarded a great example of asking “Why?” persistently until the root cause is found. Why are U.S. standard railroad gages 4 feet 8.5 inches? Rome. You can find the full story on this bull

Lean Culture in a Temporary Workforce

By Jon Miller - March 1st, 2007

Can you have Lean manufacturing without Lean enterprise? Can you have Lean enterprise without a Lean culture? Can you have Lean culture without a motivated shop floor? All of the trappings of operational excellence such as one piece fl

Lean Six Sigma is Not Lean

By Jon Miller - February 21st, 2007

Lean Six Sigma is not Lean. It is Six Sigma, but one that is more “Lean” than just regular “Six Sigma.” In the English language the adjective (Lean) modifies the noun or subject word (Six Sigma). So Lean Six Sig

Getting the CEO on a Kaizen Team is Like Pulling Teeth

By Jon Miller - February 19th, 2007

As I was flipping through my copy of the February 2007 issue of Dental Economics today, an interview with two Danaher executives caught my eye. Danaher is known as a leading American company who has quietly and profitably grown through

Rarely Has Ranting Been This Good

By Jon Miller - February 12th, 2007

Blogger BDG123 at Rantings on Markets, Economics and Business Strategy is an electrical engineer and mathematician by training, one-time corporate consultant and corporate sales and marketing executive in the information technology and

Building a Lean Video Library

By Jon Miller - February 11th, 2007

Our clients often ask us to help them with building a Lean video library. They want us to recommend 5 or 10 videos on Lean manufacturing that will help their people learn first the general concepts, then the more in-depth tools and sys

How to Calculate Standard Work in Process (SWIP) Quantity

By Jon Miller - February 8th, 2007

Standard Work is one of the more misunderstood concepts in Lean manufacturing. It is neither standardization nor work standards. You can learn more about Standard Work by looking at the following blog posts: Reflections on Standard Wor

Free Scholarship at the Lean Six Sigma Academy

By Jon Miller - January 28th, 2007

My friend Ron Pereira started a blog two weeks ago called Lean Six Sigma Academy. The articles so far have been an interesting mix of topics such as Process Mapping – Lean or Six Sigma Tool?, CAVE People, Lean or Six Sigma?, Six

Lean Manufacturing: A Five-Year Fix?

By Jon Miller - January 24th, 2007

On the way to the gemba this morning I heard the NPR report on American suit manufacturer Joseph Abboud on the rental car radio. Here is the transcript on the NPR website, titled Suit Maker Goes ‘Lean’ to Keep Jobs in U.S.

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