Six Sigma is quality. Lean is speed. The synergy of both is the most powerful engine available today to sustained value creation. Six Sigma was developed as a quality improvement system by Motorola and gained widespread traction in the 2000's with high profile adoptions by General Electric, Honeywell, and others. Lean originated out of the Toyota Production … [Read more...]
A value stream map is a tool used in lean manufacturing to identify and communicate the value-producing processes within a factory. Value stream maps utilize a standard set of industry recognized symbols to map out the plant's processes, from raw material to finished product. Value stream maps are used to improve the plant's processes, perform continuous … [Read more...]
Value stream maps are diagrams used in lean manufacturing which identify each step of the manufacturing process. They are used to determine the value stream, that is, the steps that result in the creation of value. Their purpose is to visualize the manufacturing process so that anything that is not necessary to create the product of value can be … [Read more...]
Jidoka is the ability of machines and assembly line workers to detect when a quality non-conformance issue has occurred and immediately stop the production line to make the necessary improvements to the process. Jidoka originated in the Toyota Production System, where it was not just the worker's right to "pull the cord," but their responsibility. Far from leaving … [Read more...]
Human beings are naturally predisposed to resist change because of the risks it entails. Maybe the change will fail. Maybe it will reduce business or personal income. And maybe it will result in a loss of job security. We'd rather the devil we know, than the devil we don't. But process improvement is often an exciting step forward that makes an … [Read more...]
If there is one enemy of business success, it is this: Wastefulness, inefficiency, and uselessness. This is the definition of the japanese word muda, a household name in lean manufacturing circles but an infinitely valuable one for every business professional who learns to root out and destroy this sprouting cancer at every available opportunity. In lean … [Read more...]
Takt time is a lean manufacturing concept which represents the exact rate at which a plant must produce its product to satisfy demand. It is measured in time per production step (minutes, hours, etc.). Although order levels fluctuate for many products and factories, the underlying demand tends to be constant. Hence, the production rate of the plant should … [Read more...]
Kaizen is a component of Lean Manufacturing which involves the steady, systematic removal of waste from the production line. In a lean facility, the components of the manufacturing process that produce value (the "value stream") are identified, and everything that is not absolutely necessary to produce that value is considered muda, japanese for waste. Kaizen, … [Read more...]
Starting from a point of almost complete ruin after World War II, the Toyota Motor Company rose to become the largest car maker in the world in the mid-2000's. This resulted in many inquiries into the source of their success. Starting in 1988, the engineers and architects of Toyota's success began to open up. As a result, the Toyota Production … [Read more...]
Lean Project Management is the application of lean concepts to project management methodologies. Lean is a method used in the manufacturing industry which results in significant increases in product quality and production efficiency. Project management, on the other hand, seeks to produce one single product or service (or just a few) while satisfying stakeholders … [Read more...]
