Category Archives: Success

Success stories, but also major failures in the hope that you won’t repeat these.

Lies, Damned Lies, and KPI – Part 3 Countermeasures

Kid with Glasses
How to measure good KPIs

There is an inflation of key performance indicators (KPIs) in industry. In my last posts I have explained how KPIs are often wrong, and why bad and fudged KPIs are a huge waste. Yet, you cannot really run a larger corporation without KPI. In this post I will finally give some advice on (1) what you need to do to measure good KPI, and (2) how to avoid fudged KPI. Continue reading Lies, Damned Lies, and KPI – Part 3 Countermeasures

Lies, Damned Lies, and KPI – Part 2: Effects of Fudging

Business fraud
About the ills of number fudging

Modern manufacturing works with a lot of performance measures, often called key performance indicators (KPIs). Unfortunately, they are rarely accurate, and often even intentionally misleading. In my previous post I described some examples of commonly manipulated KPIs. In this post I would like to explain the ugly consequences of incorrect or manipulated KPIs. In a final post I will also show some ways that you can reduce this negative effect. But first, how do bad KPIs (and hence most KPIs) hurt your company? Continue reading Lies, Damned Lies, and KPI – Part 2: Effects of Fudging

Shop Floor Etiquette – Part 2

A little courtesy often goes a long way!
A little courtesy often goes a long way!

This is the second post of a two-post series on shop floor etiquette (first post here). I find this a very necessary post, as I have way too often observed visitors to the shop floor lacking manners (and occasionally, I may have lacked manners myself 🙁 ). Hence, please do not treat this post as optional, but try to incorporate it into your daily shop floor work. Being accepted on the shop floor is crucial for any successful change on the shop floor. Continue reading Shop Floor Etiquette – Part 2

Shop Floor Etiquette – Part 1

Greeting
A little courtesy often goes a long way!

There is often a distinct lack of appreciation and good manners toward shop floor employees. Yet, lean manufacturing happens on the shop floor. Not in Excel, not in PowerPoint, not in meeting rooms. As such, you need to become part of the shop floor in order to change the shop floor. For this, you need the support and goodwill of the people on the shop floor. The first step to getting their support is to have good shop floor manners. Due to the length of the post, I have divided it into two posts. These two posts will give you some guidelines on how to behave on the shop floor. (The second post is here) Continue reading Shop Floor Etiquette – Part 1

The Folly of EPEI Leveling in Practice – Part 2

LevelingIn my last post, I started to show the main reasons why EPEI leveling with a fixed repeating schedule so often fails (for details on EPEI leveling, see Theory of Every Part Every Interval (EPEI) Leveling). This post continues with more reasons and also gives some advice on how to reduce the damage or even increase its chances of success. It also has a suggestion for a test to determine if your system is ready for leveling.

Again, there seems to be a lean religion that claims that putting up a leveling box will lead to salvation. Well, Lean is not a religion or magic. Lean is hard work, and you actually need to understand what you are doing. Just copying something without understanding is a good way to fail, especially with leveling. Continue reading The Folly of EPEI Leveling in Practice – Part 2

The Folly of EPEI Leveling in Practice – Part 1

LevelingIn my last post I presented the EPEI leveling pattern (also known as EPEC, EPEx, Heijunka, fixed repeating pattern, or simply leveling). While in theory this approach looks pretty solid, in my experience it rarely works in practice. In fact, most of these types of leveling that I have seen were complete rubbish. They were a dog-and-pony-show to please management at the expense of performance and shop floor efficiency.

Furthermore, lean manufacturing seems often to be confused with a religion. People believe that if you put up a leveling box your manufacturing system will have salvation. Well, Lean is not a religion. Lean is hard work, and you actually need to understand what you are doing. Just copying something without understanding is a good way to fail, especially with leveling. Continue reading The Folly of EPEI Leveling in Practice – Part 1

A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)

Trumpf LogoHalf a century ago, Toyota started to develop its Toyota Production System, the archetype of every lean manufacturing system. Almost every manufacturing company nowadays seems to try to implement lean manufacturing. At the same time, most also seem to fail miserably, creating a lot of huff and puff with little benefit. However, occasionally there are (very) few companies that have implemented lean manufacturing successfully. Trumpf and its Synchro production system is such a successful example of Lean manufacturing, and one of the finest production system for machine tool builders. Due to the length I have split this post into two parts. This is the second part. Continue reading A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)

A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)

Trumpf LogoHalf a century ago, Toyota started to develop its Toyota Production System, the archetype of every lean manufacturing system. Almost every manufacturing company nowadays seems to try to implement lean manufacturing. At the same time, most also seem to fail miserably, creating a lot of huff and puff with little benefit. However, occasionally there are (very) few companies that have implemented lean manufacturing successfully. Trumpf and its Synchro production system is such a successful example of Lean manufacturing, and one of the finest production system for machine tool builders. Due to the length I have split this post into two parts, the second part being available here. Continue reading A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)