Whenever you work with people, the impression you make on these people is important. Your clothes and behavior have a great influence on this impression. This post discusses strategies for your appearance to increase your chances of success on lean manufacturing projects.
Toyota is a company that is constantly evolving, aiming to reduce waste. Over the last few years, I have heard about changes to the Toyota assembly lines to improve efficiency. During a recent trip to Japan, I was able to observe the assembly line at the Motomachi plant. In this post I will show the evolution of line layouts at Toyota.
Lean manufacturing pull systems use both FIFO lanes and supermarkets to manage the material and information flow. In my previous post we covered the basics about supermarket and FIFO lanes. Now we go into details about the ten rules when to use a supermarket instead of a FIFO.
It is generally accepted knowledge that a lean manufacturing pull system uses both FIFO lanes and supermarkets to manage the material and information flow. However, there are few guidelines on when to use a supermarket and when to use a FIFO lane. This post is the first of a two-part series that will give ten general rules of thumb for when to use a supermarket instead of a FIFO lane. The second post will go into more detail about the ten rules.
The concept of lean manufacturing originated on the shop floor at Toyota. Since then it has expanded into many other areas, including but not limited to lean healthcare, lean administration, lean logistics, lean services, lean hotel, lean military, lean banking, or any lean whatever topic. There is even a lean government, albeit I am somehow skeptical on that one. Even so, most practitioners of lean work in manufacturing. Hence it comes as no surprise that most lean efforts are focused on the shop floor. However, while there is usually much improvement potential on any given shop floor, it is not necessarily the area you most want to improve.
Lean happens on the shop floor. When working hands-on in manufacturing, there are a number of items that can help you. Throughout the years I have optimized a small lean toolkit that I bring with me for my everyday practical work. Here are seven gadgets that help me to do lean on the shop floor.
Due to popular demand related to my two posts on “Make Your Plant Tour a Success!” and “How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!,” I have created a checklist for a lean visit to a manufacturing shop floor for you to download. Take this checklist with easy-to-use metrics during your shop floor visit to make yourself independent of potentially misleading data given to you by the shop floor staff. Metrics include worker utilization, machine utilization, inventory reach and turnaround, and order & cleanliness.