Reducing Lead Time 3 – Throughput and Lot Size

Traffic JamTwo more factors for reducing your lead time are the throughput and the lot size. However, the throughput has a smaller effect – although with other benefits that are often larger than the reduction in the lead time. The reduction in the lot size can have a huge effect, although usually only for make-to-stock production. Nevertheless, both are worth looking at if you want to reduce the lead time.

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Reducing Lead Time 1 – Inventory

Supermarket CheckoutLead time is a key factor for customer satisfaction, especially with make-to-order production. Hence, many companies want to reduce this lead time. In this blog post I show you the basic levers that influence your lead time, and a few more that may also apply to some cases. You have to find the combination of these levers that works best for you. This is the first post in a series of four posts on how to reduce lead time. Most of the series focuses on production, but the last post looks into reduction of lead time in development.

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What Is True North in Lean?

True NorthLean manufacturing often talks about true north. This is the direction in which your operations should move to become better. Sometimes that may be a bit fuzzy, so let’s have a look at what true north could include.

I am fully aware that reaching true north in all aspects is unrealistic. If you actually reached true north, there would be nothing left to improve… which goes against my beliefs in manufacturing. You can always get better! Hence, achieving the list below is not realistic. But hey, as I am writing this, it is almost Christmas, and it is okay to make a wish! I hope that this unrealistic list helps you to get closer to true north in at least some aspects.

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The Baton Touch Flow Line

Relay Race Hand OverThe baton touch is probably the easiest way to do multi-machine handling in a line. This ease-of-use makes it a very popular approach for the assignment of the operators in a line. An operator is in charge of a fixed set of processes. The operator always repeats the same loop of processes. Multiple operators, each with their fixed assignment of processes, work on a production line together. It is quite simple.

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How to Learn Lean

Lean manufacturing can help you and your company greatly. But how do you learn lean? Of course, there are plenty of Six Sigma lean black belts and other certificates available online, but do they really make you understand lean? In this post I have some suggestions on how to learn lean. These can befollowed by people with access to an actual shop floor to work on. However, I have also included suggestions for people, e.g. students, that do not have access to a shop floor. In this case, you can do … let’s call it “Home Improvement“. Let’s have a look at some suggested actions for learning how to do lean!

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Reducing Fluctuations Downstream

This last post of my series looks at fluctuations that originate downstream from your location. In other words, how to reduce fluctuations originating from your customer. Granted, this often is the most difficult one, as you usually have not so much influence over your customers (unless you have a monopoly). Let’s have a look.

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