One popular approach to battle waste is to streamline changeovers. Changing machines from one setup to another is often a time-consuming exercise. Hence, in lean manufacturing, reducing changeover times is a well-known method for improving efficiency. This post will show a number of examples where these quick changeovers (also known as SMED) can be practiced in an unusual environment.
Mistake proofing (or Poka Yoke in Japanese) is one important way to avoid waste in lean manufacturing. In this post, I will present a small game that can be used to teach the basics of poka yoke easily and quickly. The game is based on Kinder Surprise eggs made by Ferrero, also known as a Kinder Egg. These eggs are available almost anywhere – except in the US, in which case there are some alternatives.