Foundational Concepts of Lean
Lean manufacturing utilizes a number of strategies and tools to improve the business by boosting productivity and eliminating waste. The following are just a handful of the most common Lean tools, many have been adopted from manufacturing in Japan and the Toyota Production System . 5S (The Visual Workplace) 5S is a system of creating…
Jesse Allred | June 7, 2019 | 5S, Continuous Improvement, Kaizen, Kanban, Lean, Lean Manufacturing | 5S, Continuous Improvement, Kaizen, Kanban, Lean, Lean Manufacturing | 3 min read
What is a Gemba Walk?
Gemba walks are an important concept in your Lean toolbox. Managers and business leaders go on (“go and see”) walks to observe firsthand how the production line is operating. The Objective of a Gemba Walk In businesses, managers often look to company leaders for direction. The value created by a business, though, exists out on…
Jesse Allred | February 11, 2019 | Gemba, Lean, Lean Manufacturing | 5S, Facility Efficiency, Gemba, Kaizen, Lean Manufacturing | 3 min read
The 5S Shine Pillar – Inspection and Maintenance
The third step of 5S is Seiso, a Japanese term translated to mean Shine. During Shine, workers are encouraged to do a deep cleaning of their space, ensuring there is no grime, dust, or oil spills remaining. However, it is important to remember that cleaning is not the only facet of this phase and that…
Jesse Allred | January 15, 2019 | 5S, Lean, Lean Manufacturing | 5S, Facility Efficiency, Lean, Lean Manufacturing | 2 min read
The Toyota Production System House
The Toyota Production System, or TPS, is a widely-used and successful production system in manufacturing that focuses on reducing and eliminating waste, while producing quality products for consumers. The TPS model was developed by the Toyota Motor Corporation for their vehicle production system, but the principles and activities it encompasses can be applied to nearly…
Jesse Allred | September 20, 2018 | Kanban, Lean | Continuous Improvement, Facility Efficiency, Lean Manufacturing | 3 min read
How do you make a Factory Culture Embrace Lean?
Several years ago, I was working as a project manager for a local manufacturing company. The owner asked me how much I knew about lean, and I told them I had about three years experience working on a lean transformation in upstate New York in which we had to completely change the factory climate from…
Tony Ferraro | November 17, 2013 | Lean | Continuous Improvement, Facility Efficiency, Kaizen, Lean Manufacturing | 2 min read
Lean Is More Than Its Tools
I talked with a guy yesterday about 5S and how well it would work at his office. I asked him what the problem was, and he said, “Oh, you know, it’s messy and I want people to be tidier.” I didn’t laugh or anything, but I let him know that 5S, under the larger lean…
Tony Ferraro | November 3, 2013 | Lean | 5S, Facility Efficiency, Lean Manufacturing | 2 min read
How to Organize Your Shop: Try 5S
Are you needing some organization in your workshop? Do you spend more time trying to find tools and supplies and less time actually working? Are you hoping to improve your efficiency and cut your waste down? Would doing all of this help to improve quality to the customer and possibly even reduce prices? Well, you…
Tony Ferraro | October 1, 2013 | 5S, Lean, Lean Manufacturing | 5S, Facility Efficiency, Lean, Lean Manufacturing, Organized Workplace | 3 min read
What is 5S and How Should We Implement It?
5S is, in the simplest terms, a method of creating, maintaining and improving a workplace which is clean, orderly, and has methods for detecting waste and errors built in. When used properly, it will help to identify areas where things are being done inefficiently, and come up with solutions for improvement. It will help to…
Tony Ferraro | September 4, 2013 | 5S, Lean, Lean Manufacturing | 5S, Facility Efficiency, Lean, Lean Manufacturing | 2 min read
Executing a 5S Launch
If you’re considering implementing a 5S system in a facility, it is essential to take the time to do it right. When done properly, the 5S system can be an effective way to clean and organize a workplace, allowing it to run more efficiently. If the 5S launch isn’t well thought out, it can lead to disaster.…
Tony Ferraro | September 4, 2013 | 5S, Lean, Lean Manufacturing | 5S, Facility Efficiency, Lean, Lean Manufacturing | 3 min read
Connection Between 5S and Lean
In order to have a good understanding how 5S and lean concepts are connected, is important to first take a look at them separately. 5S is a way of measuring the implementation of lean manufacturing techniques. It is the foundation which is used to support lean manufacturing strategies from the beginning until full implementation. Lean manufacturing,…
Tony Ferraro | August 21, 2013 | 5S, Lean, Lean Manufacturing | 5S, Facility Efficiency, Lean Manufacturing | 2 min read
Importance of Catchball
The catchball is an important part of any planning process, but it is something that is all too often just glossed over. When done properly the catchball encourages leadership and team members to dialogue about a particular topic in an efficient and productive manner. It can help to break down the walls which are all…
Tony Ferraro | July 22, 2013 | Kaizen, Lean | Continuous Improvement, Facility Efficiency, Kaizen, Lean Manufacturing | 2 min read
The Lean Manager
Getting started as a lean manager can be a daunting task because in many cases people don’t really understand what it is you’re supposed to be doing. In many cases the lean manager will also have other roles within the facility, and has been given the task of implementing lean concepts as well. One of the most…
Tony Ferraro | June 25, 2013 | Lean | Continuous Improvement, Facility Efficiency, Lean Manufacturing | 2 min read
Taking Advantage of your IT Staff to Implement Lean
When evaluating a facility for ways to improve efficiency and implement lean standards there are many different areas to observe. For most companies it is important to take advantage of the IT staff when planning and implementing any changes or improvements throughout the facility. While IT won’t be able to assist with every single step…
Tony Ferraro | April 24, 2013 | Lean | Facility Efficiency, Lean Manufacturing | 2 min read
Kanban Systems
Kanban systems are an important scheduling system used in ‘just-in-time’ production facilities. The word Kanban actually means signboard or billboard, and with these systems each part or product is only supplied as it is needed. This critical part of the just in time method of manufacturing helps to eliminate waste in a variety of ways…
Tony Ferraro | April 17, 2013 | Kanban, Lean, Lean Manufacturing | Barcoding, Facility Efficiency, Kanban, Lean, Lean Manufacturing | 2 min read
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 16, 2013 | Continuous Improvement, Lean, Lean Manufacturing, Six Sigma | Continuous Improvement, Facility Efficiency, Lean Manufacturing, Six Sigma | 2 min read
