In lean, there is a lot of talk about “learning to see,” with the goal of better understanding the shop floor. This is, of course, important. However, another important aspect is listening, both on the shop floor and elsewhere. This blog post goes deeper into why and how to listen to the shop floor, or generally the gemba.
The Benefit for Denso of Reducing Fluctuations
On the Eighth Wastes of Unused Human Creativity
Reducing or eliminating waste (muda) is one of the approaches to lean manufacturing. Traditionally, Toyota uses seven types of waste. In the Western world, an eighth type of waste is also often used, namely “unused human creativity.” There is much discussion whether this is a good, useful waste to analyze or not. As I started to write this article, I saw this type of waste as not so helpful in lean manufacturing. Colleen Soppelsa, whose opinion I respect very much, on the other hand, sees it as a very helpful type of waste. Time to sort out my thoughts and reconsider the pros and cons of including “unused human creativity” in the lineup of the types of waste. Maybe by the end of this article I will change my mind. Let’s see…
Kaizen: Hoshin Kanri, Bowler Charts, Action Plans, and More
In my last two posts I described bowler charts, named due to their similarity to the score charts used for bowling. In this post I want to talk a bit more how the bowler chart fits in the big picture… or, if you will, how the big picture can use a bowler chart.
This will be a big picture on kaizen improvement. First you need your true north, which allows you to set your overarching targets (e.g., in a hoshin kanri). To reach the overarching targets in the hoshin kanri, you need practical problem solving, A3s, or an Action plan to make actual improvements toward your overarching goals. Underlying all of this is of course the PDCA. But, let me show you in more detail:
The Bowler Chart—Caveats and Improvements
The bowler chart, or bowling chart, is a table that is used to track the progress of an improvement project, deliverable, or task. Its name comes from the high similarity to the bowling score sheets that are used to track the progress during a bowling game. In my last post I also explained possible pitfalls with the owner, the projects, and the numeric target. This post continues with more caveats on target progression and the use of color, before suggesting a possible improvement to make the progress even more visual. (Spoiler: Use a diagram!). But, read on…
The Bowler Chart—Tracking Your Projects
Hoshin Kanri (or “policy management” in English) is a way to manage the objectives of both you and your people and also align these objectives with the overall goals and directions of the company. One possible and useful companion document to track the progress of these objectives throughout the year is the bowler chart, or bowling chart. In general, this chart can be used to track the progress of an improvement project. Let me give you an introduction to bowler charts.
On Leveling and Fluctuations—How Does Toyota Do Leveling?
On Leveling and Fluctuations—The Downsides of Leveling
In my last post I gave you a brief introduction to fluctuations and leveling. And, I already hinted that there are two downsides to leveling: properly set up it handles only fluctuations coming from upstream, and—what is rarely talked about—there is an increase in inventory and/or waiting time to decouple the fluctuations in leveling. The second one especially is widely ignored or even vehemently denied in industry, but it is definitely there. Let me show you!