lean manufacturing
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What is happening in lean manufacturing in the world
Curated by Michel Baudin
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Lean principles are saving Saskatchewan healthcare millions of dollars - News Talk 980 CJME

Lean principles are saving Saskatchewan healthcare millions of dollars - News Talk 980 CJME | lean manufacturing | Scoop.it
Lean principles are saving Saskatchewan healthcare millions of dollarsNews Talk 980 CJMEThe government of Saskatchewan is boasting savings of some $60 million in the healthcare industry thanks to what they're calling Lean concepts.
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Toyota Manufacturing Celebrates 40 Years in the US at Long Beach - Auto World News

Toyota Manufacturing Celebrates 40 Years in the US at Long Beach - Auto World News | lean manufacturing | Scoop.it
Auto World NewsToyota Manufacturing Celebrates 40 Years in the US at Long BeachAuto World NewsAnd over these 40 years, we have proven ourselves as a world-class manufacturer with an outstanding workforce that's dedicated to safety and quality." TABC...
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Drives & Controls :: News :: World news :: Linear systems are produced in `batches of one`

Drives & Controls :: News :: World news :: Linear systems are produced in `batches of one` | lean manufacturing | Scoop.it

Festo has implemented a manufacturing system that allows it to produce parts for linear handling systems economically in batch sizes of just one item. At its global production centre for electric and pneumatic drives at St. Ingbert-Rohrbach in Germany, the company has introduced a “one piece flow” method of assembly, based on Toyota’s production system.

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GE press release on Newest Dishwasher Production Line

GE press release on Newest Dishwasher Production Line | lean manufacturing | Scoop.it

The first phase of a $150 million investment in GE’s dishwasher plant and product line is creating 100 new jobs, incorporating lean manufacturing.

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Brillopak wins lean manufacturing innovation award

Brillopak wins lean manufacturing innovation award | lean manufacturing | Scoop.it
The company was chosen as an inaugural winner of the Medway Innovation Voucher, towards the development of its new lean production control package. This is being developed to support small and medium manufacturers, using Brillopak’s new COMPACT C Series and robot cell packing and palletising solutions.
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Was Six Sigma A Fad? Search Trends Indicate Waning Interest | The ...

Was Six Sigma A Fad? Search Trends Indicate Waning Interest | The ... | lean manufacturing | Scoop.it
"[...] lean has enjoyed a roller coaster search history, but taken on average, it has been relatively consistent since search results have been recorded since 2004 worldwide. Six Sigma, on the other hand, has been dealing with a sliding board of interest.  It seems it might be on its way out.  Perhaps it was more of a fad than some holistic “cure-all” for industry.  I thought it was interesting to compare the main searcher for “lean” in industry, India, to my country, the United States, to see how we both seem to rank the terms.[...]"
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VOLKSWAGEN AG : ŠKODA AUTO opens new “Lean Center” - 4-traders

VOLKSWAGEN AG : ŠKODA AUTO opens new “Lean Center”4-tradersŠKODA AUTO opened its new "Lean Center" in Mladá Boleslav. This training centre will school staff and suppliers regarding optimised processes in production and in administration.
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Another article that confuses Lean with reckless

This is yet another article that equates a Lean supply chain with one that is unprepared for disasters.

 

See http://wp.me/p1UTIj-ts for the actual Lean approach to disaster recovery.

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Team building at work

Team building at work | lean manufacturing | Scoop.it

"According to a recent survey of over 1,000 U.S. office workers conducted by Wakefield Research Study (and commissioned by software company Citrix), three out of every four workers (74%) dislike participating in at least one of their company get-togethers."

 

I have long thought of these "fun" activities as inappropriate and counterproductive. Inappropriate because they are an invasion of privacy. Leisure activities are supposed to happen with friends and family outside of work, not with co-workers and bosses at work. Being playmates  is not what they signed up for when they joined. It is counterproductive because it shows disrespect for the work. You build teams by having people work in teams on projects, not by playing silly games.

 

According to the survey, "team-building" actually is second to costume contests for unpopularity: "[...] anything that smacks of “team-building” similarly gets the thumbs-down from employees, with 31% saying they dislike these activities."

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30 years later, Honda evolves - The Detroit News

30 years later, Honda evolves - The Detroit News | lean manufacturing | Scoop.it

This article discusses the "renowned lean manufacturing and 'just-in-time' production techniques of the Japanese manufacturers," a wording that implies that all Japanese manufacturers use variants of the Toyota Production System (TPS). It is not the case, and it is particularly not true of Honda. 

 

Honda is good at manufacturing, but uses methods developed in-house, based on the founder's philosophy of self-reliance.Soichiro Honda was known for telling engineers: "Don't try to find out what the other guy is doing, just solve your own problem!" He also got the company involved in racing early on so as to infuse the "racing spirit" in everything it did. The Honda Way isn't just a rebranding of TPS or Lean, as so many companies' "Production Systems" are; it is an original, autonomous development. The white uniform in the picture is part of it. Its purpose is to make stains stand out, so that their sources are identified and removed from production.

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How Toyota uses kaizen for efficiency - Business Today - Business News

How Toyota uses kaizen for efficiency - Business Today - Business News | lean manufacturing | Scoop.it

Where you learn that Toyota India ranks number one globally in the shipping quality audit, an annual exercise carried outat Toyota facilities worldwide.

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Why Toyota is Lean...and You're Not

Why Toyota is Lean...and You're Not | lean manufacturing | Scoop.it

Jeffrey Liker on what Lean really is. An interesting article, with which I have a few quibbles:

1.The Shingo Prize rewards companies for looking Lean, not being Lean, as evidenced by the prize's inability to predict competitive performance (See http://bit.ly/Lp23DY).

2. The Machine that Changed the World and Lean Thinking introduced the word Lean, not the concept. It existed before, for a good 10 years, under a succession of names that didn't catch on as well as Lean did, including TPS, WCM, and others.

3. His conclusion is overly optimistic: "At the end of the day U.S. manufacturers that invest in developing skilled, motivated leaders whose passion is to develop people who can improve processes in the long-term will beat the competition every time." I don't think it's true, because they will be competing against manufacturers elsewhere doing the same.

I also do not see this statement as an accurate summary of Lean. Under Alfred P. Sloan's leadership in the 1920s, GM did everything the statement says. When Peter Drucker wrote Concept of the Corporation in 1946, GM was arguably the best run company in the world, particularly in leadership development, but, even looking back, you wouldn't call it Lean.

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Photos of SSJ 100 Nose and Rear Production - English Russia

Photos of SSJ 100 Nose and Rear Production - English Russia | lean manufacturing | Scoop.it

The Chkalov factory makes nose and rear sections for the Superjet 100, Sukhoi's entry in the regional jet market, in competition with Embraer and Bombardier. While praised for its design, the Superjet 100 has been late in ramping up production and its future is in jeopardy following a crash during a demonstration in Indonesia on May 9, 2012. 

 

According to the article, the plant has a Lean program in place. Based on the photographs, the manufacturing concept is fixed-station assembly with kitting.

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Taking a Stand at Work

Taking a Stand at Work | lean manufacturing | Scoop.it

The notion that production work should be done standing has been controversial in Lean implementations, and resisted in particular by experts in ergonomics. Now several health researchers are saying that sitting is about as healthy for humans as smoking.

 

This article is about Anup Kanodia, form Ohio State's Center for Personalized Health Care, and his recommendation to reorganize offices for stand-up work. See also NASA's Joan Vernikos's Sitting Kills Moving Heals (http://amzn.to/Rivvlf)

 

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Decisions about Making Decisions | Lean / Six-Sigma content from IndustryWeek

Decisions about Making Decisions | Lean / Six-Sigma content from IndustryWeek | lean manufacturing | Scoop.it

Good points. On the issue of delegation, I apply the "sleep-at-night" test. You can delegate the authority to make a decision, but not the responsibility. Can you sleep at night knowing that you will be accountable for a decision that you let another person make? If you can't, stay in the loop. Once you trust the person, get out of the way.

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The History of Lean Manufacturing Practices

Sometimes the internet gives you the most surprising set of statements about a topic. Here are a few from this article:

1. "Lean training came out of an industry program known as Six Sigma." Oh yeah?

2. "Six Sigma refers to the levels of training [...] where different color belts are awarded, similar to judo." So each color of belt is a sigma? And the sigmas have nothing to do with process capabilities and defects?

3. "Kaizen [...] became known in the United States after World War II, when Japanese manufacturing techniques were being closely examined following the war." This is the first time I hear of Americans going to study advanced manufacturing in Japan in 1945. I thought we were the ones who had sent expert to teach things like TWI or SQC to Japanese manufacturers.

4. "The Kaizen methods [...] recently have been incorporated into the broader philosophy of lean manufacturing." And I thought Kaizen had been part of Lean since day 1.

 



 

 

 

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Lean und Kanban: Poker Chips, Kanban and Buffets

Lean und Kanban: Poker Chips, Kanban and Buffets | lean manufacturing | Scoop.it

An approach to improving the experience of using a buffet that relies on capping the number of people with concurrent access. It is like the nightclub or museum management system in which a fixed number of visitors is allowed in, and the next one only allowed in when one leaves.

 

This is in the same spirit as the purely production control approach to Lean, in which you change production planning and scheduling but you don't redesign the production line itself. For pointers on buffet design, see http://wp.me/p1UTIj-28.

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Hansgrohe uses Kanbans with RFID chips

Hansgrohe uses RFID-enabled kanban (signal) cards to track the flow of containers between its two production sites. The company now enjoys several benefits, including accelerated goods receipt and the certainty of having ...
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Fiat Plant Wins Prestigious Production Award

Fiat Plant Wins Prestigious Production Award | lean manufacturing | Scoop.it
The Fiat plant at Pomigliano D'Arco has been awarded the prestigious international Automotive Lean Production 2012 award in the OEM category, following an analysis and evaluation process by a committee of experts selected by the German...
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Cellular manufacturing for web-customized wedding dresses

Cellular manufacturing for web-customized wedding dresses | lean manufacturing | Scoop.it

"...rather than be part of a large group working on an assembly line, workers are divided into small teams, with each one headed by a high-skilled leader. The cells each produce three or four dresses a day according to very specific designs that require a lot of handwork. Taken in total, each company can produce about 200 dresses a day that way, with each cell producing a very different dress..."

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The Trouble with On Line Education…mis fire by NY Times op ed | The High-Velocity Edge

Steven Spear on the value of on-line education. I agree with him, but struggle with the challenge of on-line education for manufacturing. For math or programming, it is straightforward, and there are already models in place that work.

 

Spear describes cases of on-line participants in management classes using multiplayer technology tor collaborative problem-solving.But what about manufacturing?

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ISO 9001: Conspicuous by Its Absence | Quality Digest

ISO 9001: Conspicuous by Its Absence | Quality Digest | lean manufacturing | Scoop.it

To paraphrase My Cousin Vinny, this is a lucid, intelligent, well thought-out argument for the usefulness of ISO-9001: you don't hear about its benefits because they come in the form of problem-prevention.

Levinson is persuasive, but I can't help thinking that we should still be able to see before-and-after metrics of quality for companies that implement ISO-9001. The results don't have to be immediate, but they have to exist.

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Lean and 'Lawrence of Arabia' - Los Angeles Times

Lean and 'Lawrence of Arabia' - Los Angeles Times | lean manufacturing | Scoop.it

It has been a while, but it just happened again: a search on Lean brings up Lawrence of Arabia. In 1995, it was systematic, but I hadn't seen it since. If you are wondering what the connection is, the movie is a David Lean production.

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A survey of 30 company-specific production systems

A survey of 30 company-specific production systems | lean manufacturing | Scoop.it
It has become extremely popular for companies in any business to pursue the principles of lean production, Six Sigma, TQM, TPM etc (even if the two latter are a bit “so 90s”…) A n...
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Airbus Starts Production Of The A320neo Family | IFExpress

"...The Airbus Saint-Eloi site is specialised in the design, manufacturing, assembly, equipping and testing of engine pylons and design and manufacturing of titanium nacelle parts for all the aircraft in the Airbus family. Featuring the latest efficient ‘moving-line’ lean-production concept, the facility is also the leading European centre for hard metals machining and transformation, including titanium..."
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