Continuous Improvement

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Heijunka – Creating Flow

Heijunka – Creating Flow

The word Heijunka is often used in the manufacturing industry, and it means sequencing, or smoothing of production. The idea behind this term is to help absorb sudden fluctuations or changes in the demand of the market. This is often done by producing several different models of a product, in smaller production batches. In practice,

Tony Ferraro | October 9, 2013 | Continuous Improvement, Lean Manufacturing | Continuous Improvement, Facility Efficiency, Lean Manufacturing





4 Tips to Improve Workforce Efficiency within Your Warehouse

4 Tips to Improve Workforce Efficiency within Your Warehouse

Improving workforce efficiency is an important task of any warehouse manager. According to a recent survey most managers recognize the fact that their facility is not running at optimal efficiency, but they feel there is little they can do about it. While most warehouse managers may know that their facility is not running as it

Tony Ferraro | July 26, 2013 | 5S, Continuous Improvement, Kaizen, Safety | Continuous Improvement, Facility Efficiency, Lean Manufacturing


Kaizen Continuous Improvement

Kaizen Continuous Improvement

What is Kaizen? Many people mistakenly think that Kaizen is only used for short-term improvement events and other one-time improvement hits. The fact is, however, Kaizen should be used to help build a culture of continuous improvement in a facility. This will include scheduled events but it should continue much longer than that. The following

Tony Ferraro | June 27, 2013 | Continuous Improvement, Kaizen | Continuous Improvement, Facility Efficiency, Kaizen, Lean Manufacturing


Operator Based Care

Operator Based Care

The idea behind operator based care is that people who work with a particular piece of machinery are the ones who are best suited to identify and perform the general day to day maintenance of the machine.  They will notice, for example, if the machine starts making an odd noise or is running low on

Tony Ferraro | May 16, 2013 | Continuous Improvement | Facility Efficiency, TPM


Six Sigma and More

Six Sigma and More

As most people are aware, six sigma is a concept of process measurement and improvement used by many companies around the world.  The goal in any six sigma process is to have no more than 3.4 defects per million opportunities.  An opportunity is any specific task which is performed.  It could be anything from the manufacturing of

Tony Ferraro | April 17, 2013 | Continuous Improvement, Lean, Lean Manufacturing, Six Sigma | Continuous Improvement, Facility Efficiency, Lean Manufacturing, Six Sigma