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Using Kaizen with Kanban

Kanban, translated to mean visual card or sign, is an extremely helpful too for manufacturing facilities that use pull systems or the Just-In-Time system. A kanban system utilizes visual communication…

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Lean Way to the Danger Zone

3 min read

Looking for motivation on industry topics, I searched around various sites and stumbled across an article on lloyds.com called Building Supply Chain Resilience. The article brought up something that I hadn’t written about yet; lean manufacturing, like most engineering decisions, has risks. This article specifically refers to the natural disasters in 2011 that left large businesses crippled and the negative effects that lean principles have in such cases.

The crippled, or even destroyed, businesses were suppliers for other businesses and manufacturing facilities, which then sell their finished goods to retailers. The effects of disasters reach deeply into the affected industries. Lean manufacturing principles, specifically just-in-time (JIT) production, emphasizes low inventory levels of raw materials, work-in-process, and finished goods so as to minimize costs. For companies that are in the affected disaster area, JIT is ideal because it means losses were minimized. However, if you practice JIT production, what happens when your supplier unexpectedly shuts down or is destroyed by a natural disaster? (more…)

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“No Problem” is a Problem

2 min read

Most people don’t like problems and will make an effort to avoid them. More importantly, if there is a problem, nobody really enjoys admitting it, especially if that person is directly responsible for it. Managers may feel this way about the processes that they supervise. Managers shouldn’t shun problems. Shunning problems leads problems to be hidden and remain unsolved. It is a false conception that they are better off if there aren’t any problems. In this case, the only problems that are solved are the ones that can’t be hidden, such as (more…)

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The “Lean Pill” Side Effects

3 min read

I stumbled across an article called Lean and Sick by Praveen Gupta. Gupta points out his gripes with lean systems, “Lean has become more of displaying numbers, reorganizing the floor and such, but still most businesses shrink as there is little focus on customers and not much impact on growth.” He has a good point. Lean does in fact help display (more…)

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