Manufacturers Focusing On “Operational Efficiencies.” December 1, 2009
Posted by Jeff Fuchs in economy, lean, manufacturing.Tags: economy, lean, manufacturing
add a comment
According to new research by consultant IDC, “manufacturers are currently re-assessing how they are doing their business and focusing on ‘operational efficiencies.’ The research on IDC Manufacturing Insights noted that the economic crisis is bringing out the best in companies.” The study suggested “that in order to compete successfully, manufacturers must focus on ‘operational excellence’ where operations support the business strategies of the company.” And “while waiting for the economic situation to improve, the study noted that manufacturers are fostering innovation which was otherwise a low priority during ‘normal business conditions.’”
Read the report here.
Lean Lament: “Lean Out” This, Boeing December 1, 2009
Posted by Jeff Fuchs in Lean Thinking, lean.Tags: culture, lean, Lean Thinking
add a comment
The term “lean” unfortunately carries some baggage. And misconceptions. Kevin Meyer at the Evolving Excellence blog focuses on a particular phrase: “lean out”. He quotes the article that recently used the term:
[Boeing VP of Business Strategy Mike] Bair called the Renton plant a “lean enterprise,” indicating Boeing plans to transfer the lessons learned to lean out the 737 production to Everett.
“Lean out” conjures up laying off people. It makes people think of “downsizing”, “right-sizing”, and other ways of saving money by body count. But these are incorrect interpretations of what is at the heart of a lean transformation. Meyer notes that lean aims to reduce waste, but more importantly that “recognition of brainpower is what real lean is about. Leveraging, not minimizing, the second pillar of lean, respect for people. Leveraging the power of human experience, creativity, and knowledge.”
Perhaps some fact-checking is in order. Either for the media that reports on lean, or for leaders who implement it.
For the post, click here.
The World’s First Lean Dentist December 1, 2009
Posted by Jeff Fuchs in Creativity & Innovation, Lean Thinking, customer focus.Tags: customer focus, lean, Lean Thinking
add a comment
Inspired by Henry Ford and lean methods, Dr. Sami Bahri of Jacksonville, Florida, set out to reform his dental practice, looking to overcome things like long waiting room wait times, chair wait times, and diagnoses. By 2005, Dr. Bahri had made serious breakthroughs. When patients are told they have appointments at set times, lasting for set durations, Dr. Bahri really means it. The benefits for the business are telling as well. Prior to 2005, it had taken Dr. Bahri seven years to pay off half the loan on his business; in 2005 alone, they paid off the second half.
I recently heard Dr. Bahri’s story at the Association for Manufacturing Excellence conference, and it is quite amazing.
For the Lean Blog post and a video interview with Dr. Bahri, go here.
Lean Methods for Aerospace and Health Care in Ontario October 30, 2009
Posted by Jeff Fuchs in aerospace, automotive, healthcare, lean.Tags: aerospace, automotive, healthcare, lean
add a comment
On his Lean Blog, Mark Graban points out an article from Canada about how Toyota (an automaker) manages to be influential to Bombardier (maker of planes) and St. Joseph’s Hospital in Hamilton, Ontario (a fixer of people).
A sample of the results from St. Joseph’s:
Since the new system was implemented, St. Joe’s wait times have fallen on average by a couple of hours per patient, Dr. Smith said. Roughly 90% of St. Joe’s patients now have a wait time of less than four hours, as opposed only 50% before, he added.
See the original article here.
See Mark’s analysis and comments here.
Lean at Windsor’s Hotel-Dieu Grace Hospital October 30, 2009
Posted by Jeff Fuchs in healthcare, lean.Tags: healthcare, lean
add a comment
Mark Graban points to a video from Hotel-Dieu Grace Hospital (HDGH) in Windsor, Ontario Canada about their Lean effort, the video is part of their main Lean page.
See Mark’s post here.
Hotel-Dieu Grace is a member of the Healthcare Value Leaders Network.
Building From the Basics January 19, 2009
Posted by Jeff Fuchs in Lean Thinking, Lean Tools & Techniques, six sigma.Tags: lean, Lean Thinking, Lean Tools & Techniques, six sigma
add a comment
In his book, Total Quality Control, Kaoru Ishikawa described the seven basic tools of quality that could be used to solve 95% of a company’s problems. I teach these tools in my workshop on creativity and systematic problem-solving. They are, indeed, at the bedrock of process improvement, whether you are a Six Sigma wonk or a Lean Weenie. These tools are common knowledge, but they are not common practice. In many of the kaizen events and six sigma projects I audit and mentor, these tools are often misapplied or missing altogether. Get reacquainted with these essential tools to improve your process improvement efforts.
Read about the Seven Tools of Quality in Quality Progress here.
Video: Lean Doctor’s Office January 11, 2009
Posted by Jeff Fuchs in healthcare, lean.Tags: healthcare, lean
add a comment
In a recent video, a New Mexico doctor’s office shows off their 5S, visual controls, and kanban systems. It is a pretty decent clip. As Mark Graban of the Lean Blog points out, it is too bad that the reporter has to put her distracting spin on at the very end, but hey, at least the spot gets lean out there on the airwaves. The examples and the personal impressions collected in the piece more than make up for the uninformed commentary at the end.
See the clip on the Lean Blog here.
Lean Healthcare Interview January 11, 2009
Posted by Jeff Fuchs in Lean Thinking, healthcare, lean.Tags: healthcare, lean, Lean Thinking
1 comment so far
Mark Graban of the Lean Blog was recently interviewed for Healthcare Construction + Operations News. Mark is author of Lean Hospitals, and the interview is substantial and insightful. In it, Mark addresses several key questions regarding lean deployment in healthcare, particularly in hospital settings.
Read the interview here.
Unproductive Uncle Sam January 11, 2009
Posted by Jeff Fuchs in government, lean.Tags: government, lean
add a comment
Despite numerous attempts at management reform and transfer best practices between the private and public sectors, government seems to have missed out on the productivity boom seen in the private sector. That’s a shame, because while there are important differences between the public and private sectors, government does an abundance of grantmaking, procurement, property management, customer service, and other jobs ripe for productivity improvement.
This article discusses productivity within government and addresses issues such as competitive pressure, morale, the budgeting process, and the role of citizens.
Read it here.
5S for E-Mail January 11, 2009
Posted by Jeff Fuchs in 5S & Visual Management, Lean Thinking.Tags: 5S, lean
1 comment so far
In the Lean Blog, Jamie Flinchbaugh of the Lean Learning Center provides advice on how to apply 5S techniques to email. These are simple, effective tips.
See them here.
Layoff Your Inventory, Not Your Employees December 14, 2008
Posted by Jeff Fuchs in Lean Thinking, supply chain.Tags: lean, supply chain
add a comment
According to the Small Business Administration, smaller businesses employ about half the nation’s workforce and create 60% to 80% of new jobs each year. With the current economic climate, SMEs or small and midsized enterprises — like large businesses — are looking for every penny of savings to shore up resources, so they can weather this economic storm. Before cutting jobs or conducting layoffs, one place organizations can look to save big right now is in their supply chain. How a company manages its inventory can help boost the bottom line almost immediately.Between cost of money, variable storage costs and obsolescence, inventory carrying costs can range from 15% to 25% of total inventory value on an annual basis. On a million dollars of inventory, that translates to at least $150,000 of additional expense, potentially wiping out already thin profit margins.
Bill Harrison, President of Demand Solutions, explains more about how supply chain management can help small and midsized enterprises in this IndustryWeek article.
Made in America: U.S. Manufacturers Keep Their Seats in Furniture December 14, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing, supply chain.Tags: lean, manufacturing, offshoring
add a comment
In an article about the US furniture industry, the Pittsburgh Post-Gazette reported that, “more than a decade ago…cheap overseas labor and other factors threatened to turn ‘Made in America’ into an endangered species. Maintaining designers, factories and a skilled workforce became a point of pride for some companies.” For instance, American Leather’s “computerized factory contributes to the flexibility consumers enjoy with these products, making the turnaround time exceptionally quick.” Recently, it “acquired John Charles Designs, expanding its fabric offerings.” Greg Harden, President of McConnellsville, New York-based Harden Furniture Co., said that “the country is beginning to pay a price for ‘hollowing out’ the economy by allowing so much manufacturing to migrate off shore.” Harden noted that his firm “manufactures 96 percent of its product domestically.”
The article profiles American Leather, Harden Furniture Company, C.R. Laine, Kindel Furniture Company, and Hickory Chair.
Read the full article here.
Next Generation Manufacturing Strategies *Do* Work December 8, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing.Tags: lean, manufacturing
add a comment
More than 500 manufacturers who responded to the Wisconsin Next Generation Manufacturing Study found that Next Generation Manuacturing strategies are a powerful catalyst for world-class performance and success. The study was conducted by Manufacturing Performance Institute (MPI), a global research firm that annually conducts the largest study of manufacturers in the U.S.
The study identified key components of Next Generation Manufacturing strategies including: Customer-Focused Innovation; Engaged People/Human Capital Acquisition, Development and Retention; Superior Processes/Improvement Focus; Supply Chain Management & Collaboration; Green/Sustainability and Global Engagement.
Message to Manufacturers: “Catapult the Cow” November 30, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing.Tags: lean, manufacturing
add a comment
Gary Conner, author of several lean books, writes a persuasive article on the Lean Blog and offers advice and inspiration to manufacturers in the midst of the current financial crisis. As an analogy, he notes that most people have seen the scene in the Monty Python movie where a cow get catapulted onto medieval warriors during a seige. He describes the actual situation that this comical scene is based on – one that called for unusual actions in unusual times.
Conner recommends that hunkering down and waiting a few months will only get us several months deeper into trouble. Manufacturers in tough times must move aggressively – often in contrarian directions. He suggests that business focus on the diligent application of lean to deal with these tough times. Not business as usual. Not pulling back. Not becoming passive. And not a “Hail Mary”. Conner is talking about an active move forward in a new direction that gets results. “And now,” as John Cleese would say, “for something completely different.”
Read his comments here. We couldn’t agree more.
Food Industry Is Catching On To Lean November 30, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing.Tags: lean, manufacturing
add a comment
Food Manufacturing ran an article describing the background and fundamentals of lean – pretty basic stuff. But it then touches on regulatory issues, equipment, and the influence of lean on the food industry.
The Heat Is On: Designing Lean Manufacturing Processes November 25, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing.Tags: lean, manufacturing
add a comment
Watlow foundry operation in Batavia, IL produces industrial and commercial heating products. They began their lean journey in 2001 with the creation of work cells in one production area where they were able to decrease lead time by 75% and accomplish the work with 1/3 as many people. Project teams have since carried out lean initiatives throughout the entire company, from manufacturing to business processes with great success. Watlow’s systematic approach to process improvement is outlined in the article including the components of their regular kaizen event workshops.
Read the full article in Plant Engineering magazine here.
Lean Thinking in Government: The State of Iowa November 25, 2008
Posted by Jeff Fuchs in Lean Thinking, government.Tags: government, lean, Lean Thinking
add a comment
For several years the Iowa Veterans Home has used lean concepts to improve processes spanning the departments that deliver care to over 700 U.S. military veterans and their spouses. This lean case study looks at a recent kaizen event at the Veterans Home and more broadly at the five-year old lean effort in Iowa government.
Read the case study at lean.org (registration required)
Award Honors Quest Aircraft November 25, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing.Tags: lean, Lean Thinking, manufacturing
add a comment
Faced with an order backlog of 100 of its backcountry Kodiak airplanes, Quest Aircraft Co. management knew it had to speed up production time, reduce production costs, and build a work culture focused around continuous improvement. The Sandpoint, Idaho company turned to an aviation consultant and TechHelp — a consortium of Boise State University, the University of Idaho, and Idaho State University. Employees underwent lean training and implemented lean techniques to their production process. As a result, Quest Aircraft has earned a Spirit of Continuous Innovation Award. For MWCC members of this newsfeed, here is a public/private partnership that works almost as well as ours!
Read the article here.
Gary Convis Replaced as Dana CEO November 16, 2008
Posted by Jeff Fuchs in Lean Thinking, automotive.Tags: automotive, leadership, lean
add a comment
A great Lean leader, Gary Convis, has been replaced as CEO at an auto parts supplier, Dana. He will be vice-chair, however, and will “focus on developing customer relations and manufacturing quality.”
Mr. Convis, 65, was appointed to president and CEO in April. The selection followed his retirement last year as executive vice president of Toyota’s North America operations.
It has been the third change for the top job at struggling Dana in the last nine months.
For those who are familiar with the organization, Convis was the guest speaker at the Maryland World Class Consortia’s Annual Meeting this past April.
Full story is here.
Lean Manufacturing Used in Boeing F/A-18 Hornet Production November 16, 2008
Posted by Jeff Fuchs in Lean Thinking, manufacturing, military.Tags: lean, manufacturing, military
add a comment
St. Louis Commerce Magazine provides a glimpse of Boeing’s production line for F/A-18 Super Hornets. The company’s manufacturing facility near Lambert Airport in St. Louis illustrates how the company is saving millions of dollars by using lean manufacturing techniques. Some of the techniques used to manufacture the Super Hornet include optimized installation sequences, automated drilling and installation, and laser measurements.
Boeing uses a pulse-line process for assembling, moving through pulse positions. With pulsing, the aircraft does the moving, not the workers. All of the tools are right where they are needed at each station. Two workers are able to shove the plane down the line, whereas in years past it would have taken dozens of cranes to perform the task.
The lean manufacturing process at Boeing has taken the cost of each Super Hornet down from around $85 million to around $50 million, over the life of the program, says Bob Gower, vice president of the F/A-18 and EA-18 programs. The Navy has calculated that lean improvements to Boeing’s F/A-18 program has saved the taxpayer $1.7 billion.
Read the full article here.
Amazon’s “Frustration-Free Packaging” is Lean and Green November 16, 2008
Posted by Jeff Fuchs in Lean Thinking, green business.Tags: green, lean
add a comment
Amazon made some news at the end of last week when it announced that it will be redesigning its packaging and shipping practices for a variety of products. The initiative is called “frustration-free packaging” and it should be instantly clear what it involves to anyone who has ever bought a child’s toy or an electronic doodad. The idea is to eliminate the annoying and wasteful hard plastic clamshells and wire ties that trap so many of our products.
The Lean implications of this are obvious, as illustrated in the following quote from the company’s press release:
One of the first products to launch with Frustration-Free Packaging is the Fisher-Price Imaginext Adventures Pirate Ship, which is now delivered in an easy-to-open, recyclable cardboard box. The new packaging eliminates 36 inches of plastic-coated wire ties, 1,576.5 square inches of printed corrugated package inserts and 36.1 square inches of printed folding carton materials. Also eliminated are 175.25 square inches of PVC blisters, 3.5 square inches of ABS molded styrene and two molded plastic fasteners.
Read the full blog and link to the press release here.
Air Force Base Manages Hazardous Waste with Lean November 16, 2008
Posted by Jeff Fuchs in Lean Thinking, green business.Tags: green, lean, military
add a comment
Robins Air Force Base continues to benefit from efforts started nearly a decade ago when it began applying lean techniques to its hazardous waste management processes to reduce the lead time for collecting and hauling away hazardous wastes. The Warner Robins Air Logistics Center is responsible for depot-level repairs for the Air Force’s F-15 fighter aircraft and the C-5 and C-130 transport aircraft. It provides support for 11 types of cargo and utility aircraft, four series of helicopters, three types of remotely piloted vehicles, and eight missile systems. After examining the non-value added time in its process, Robins AFB instituted a new system for collecting and transporting hazardous wastes; this system eliminated process steps, saved 1,500 hours of time handling wastes, and reduced the frequency that waste drums were handled (decreasing the number of times waste drums were touched by workers by 70 percent). Robins AFB also reorganized its hazardous waste management facility using 5S and visual controls to control inventory and work in process as well as improve flow. This made it easier to monitor the waste management processes and reduced the likelihood of accidents and spills.
Read the full article here.
Lean-Trained Execs Fast-Track Green Transition November 16, 2008
Posted by Jeff Fuchs in Lean Thinking, green business.Tags: green, lean
add a comment
The recent launch of IBM’s “Green Sigma” Corporate Social Responsibility (CSR) consulting service underscores a growing realization that operational excellence principles and practices can be applied to the rapid acceleration toward green business. More and more business leaders agree that the shift to green is necessary and, when done well, can be profitable. And lean, LSS, and other continuous improvement strategies can be applied to integrated management systems as a framework for the shift to green.
Read the full article here.
Lean Repair System Debuts November 7, 2008
Posted by Jeff Fuchs in Lean Thinking.Tags: automotive, lean, maintenance repair & overhaul
add a comment
DCR Systems is touting its new “lean” operating model for collision repairs.
The new system is based on lean-manufacturing principles, which eliminates many of the inefficiencies associated with auto body repair.
“The traditional way of repairing a car involved one technician working on many vehicles,” says DCR Intellectual Property President and CEO, Michael Giarrizzo, Jr. “Part of the paradigm shift in the DCR IP system involves technicians becoming task-specific experts trained to use the latest repair technology when and where it’s required.”
Read more at: http://wardsdealer.com/ar/auto_lean_repair_system/
