In many lean books and other writing, it is often recommended to use a pencil for certain tasks as, for example, the A3 report. Yet, I have seen very few uses of pencil in lean manufacturing in the Western world. Most of the documents are computer printouts based on Excel, PowerPoint, or Word. The few handwritten documents are usually done in pen (see also my post on The Advantage of Handwritten Data on the Shop Floor).
One of the famous teaching methods by Taiichi Ohno is the chalk circle. The method itself is simple. A circle is drawn on the shop floor near a point of interest. A disciple is put in the circle and told not to leave it until he is picked up again by the teacher.
In my last two posts I described how to measure cycle times. However, for manual processes measuring cycle times is quite different, since the humans that are measured usually strongly dislike being measured. Therefore, it is difficult to measure it directly. There is an alternative to calculate it, but this also has lots of pitfalls. Let me explain you a bit about human psychology, and how to measure manual cycle times. Continue reading Cycle Times for Manual Processes→
This is the second post on how to measure the cycle time of a process. Again, the cycle time is the fastest repeatable time in which you can produce one part. Hence, as part of a series on manufacturing speed measurements I continue with more details on what cycle times really are. This is the second post on how to measure cycle times (post 1 here), with an additional third post focusing on the details of manual cycle times coming up next. Continue reading How to Measure Cycle Times – Part 2→
The cycle time of a process is a key to match the supply with the demand in lean manufacturing. Everybody working on a shop floor knows the term. Yet, I still find that people sometimes confuse what exactly it means. The cycle time is the fastest repeatable time in which you can produce one part. Hence, in this post as part of a series on manufacturing speed measurements I would like to dig deeper into what cycle times really are, and how to best measure them. As it turns out, there is actually quite some detail on how to measure cycle times, hence I split this post into two parts (second part How to Measure Cycle Times – Part 2), with an additional third post focusing on the details of manual cycle times. Continue reading How to Measure Cycle Times – Part 1→
Lean manufacturing is difficult. External expertise can help you in improving your business. However, the wrong consultant can at best have no effect, or worse damage your company, or at worst kill the company. Hence the consultant you hire will have a significant impact on the outcome of the project. This post will give you some advice on how to select a good consultant. Continue reading How to Find a Good Lean Consultant→
In my last post I detailed the 5S method (and its variants 4S, 6S, and so on). However, knowing the theory is the easy part. Successfully implementing 5S is much more difficult, and industry is ripe with anecdotes on failed 5S implementations. Here I will give you a few tips on how to increase your chances of success. However, there is no magic bullet. Cleaning and organizing a shop floor is hard work, and keeping it that way is even harder. Continue reading How to Make 5S Stick→