INTERVIEW – At last month’s International Lean Summit in Hungary, our editor sat down with the manager of a CooperVision site that is gradually converting its operations to make them leaner.
SERIES – The authors discuss the fifth of six elements in their 6CON process development model – CONfirm – leveraging a robust launch readiness approach to finalize the process while ensuring it meets the targets set in the business plan.
FEATURE – In the last article in his series, the author discusses how you can mix and combine the different pull systems available to the lean practitioner.
FEATURE – Inventory reduction is critical to waste elimination. Yet, many are reluctant to do it, fearing demand variability and production instability will neutralize their efforts. Grupo Sabó's story proves otherwise.
WOMACK’S YOKOTEN – In his first column of 2018, the author looks at one of the most talked about companies in the world, Tesla, from a lean point of view.
INTERVIEW – In this Q&A, the CEO of a Ukrainian provider of equipment for stores shares how lean thinking has helped his company modernize its processes and engage its people.
FEATURE - It took a Spanish clinical diagnostics instruments manufacturer the introduction of a new product to realize how an old-fashioned system and management style were preventing the company from thriving.
SERIES – The authors discuss the fourth of six elements in their 6CON process development model – CONfigure – refining the selected process concept to maximize value-added activities.
INTERVIEW – From hospitals to start-ups, lean principles have been applied far beyond their origins at Toyota. This article discusses how lean can be applied to learning – specifically, how we can apply lean learning to learning lean.
SERIES – The authors discuss the first of six elements in their process development model – Context – highlighting the importance of gaining clarity on the objectives of the process being created.
FEATURE – The authors discuss radical quality improvement at Toyota and introduce a new book by Sadao Nomura that the Lean Global Network has just co-published.
FEATURE – The approach described here, first adopted by this Chinese company, directly connects the daily work in manufacturing with an organization’s financial results.
CASE STUDY – Some blamed lean for the shortages of personal protective equipment (PPE) in first wave of the pandemic. This small Norwegian producer of disposable bedsheets used it to establish and ramp up the production of medical gowns for healthcare workers.
THE TOOLS CORNER – For the second article in our new series, the author offers a guide to the origins and use of one of lean's most important tools: SMED.
WOMACK’S YOKOTEN – This month, the author looks at the production line, a century-old idea that still fascinates us, reflecting on how lean thinking has changed it.
FEATURE – With an open-minded approach to improvement tools, a long history of quality and engaged top leaders, wire manufacturer Ducab aims to fulfil the strategic needs of the Emirates.
FEATURE – Setting the right buffer limits and re-order point, triggering production of an item, is critical for an organization to manage inventory. In his latest article, Ian Glenday explains why, once again, picking flow over batch logic is a no-brainer.
FEATURE – This Siemens Group-owned medium-sized manufacturer of electrical low-voltage devices has been experimenting with hoshin kanri. In this article, they share their experience and lessons learned.
FEATURE – During a recent Jishuken workshop, Poland-based Schumacher Packaging experimented with a newly-developed App to quickly create standardized work instructions at the gemba.
FEATURE – With the help of Lean Thinking, this Ukrainian producer of stainless steel pipes is retaining its competitive position against larger players in the market.
FEATURE – In the first piece of a series on Takehiko Harada’s contribution to TPS, the authors discuss the Nagara Switch and how it helps to achieve better Jidoka.
CASE STUDY – The story of this Norwegian window and door manufacturer shows how a deep and ongoing commitment to a lean transformation can help a company thrive against all odds.
FEATURE – In this compelling read, the author explains how “centerlining” tools and settings can reduce variation in a process and avoid having to constantly seek adjustments à la McGyver.
INTERVIEW – A former VP of Operations from Thales tells Catherine Chabiron how he and his team turned around their department by committing to lean thinking and focusing on people development every day.
THE NAKED GEMBA – Our new series goes back to basics to unlock the secrets of the gemba and tell us about some of the main tools and techniques we can use in a lean transformation. First up, supermarkets.
CASE STUDY – This Turkish producer of sanitaryware has boosted its quality so dramatically it’s now a player in the German market. It did so by bringing drastic change to its production system.
INTERVIEW – In this thought-provoking conversation, Michael Ballé and Mark Graban discuss metrics and the managerial attitude towards tracking them.
FEATURE – Sometimes all you need to change minds is a successful experiment. This is how a Norwegian furniture manufacturer managed to transform the way it thinks about its sofa production.
THE LEAN BAKERY – In the fourth episode in our video series, the CEO of 365 explains how lean showed him that his business could grow (exponentially) without using any extra resources.
FEATURE – How reading lean books empowered people and transformed the managerial culture at an industrial bakery in the Western Cape Winelands in South Africa.
NOTES FROM THE GEMBA – If you need proof that kaizen leads to real innovation, look no further than AIO. This French Tech company that reinvented itself as a karakuri kaizen coach.
FEATURE – Through this intimate anecdote from her days at Toyota Motor Manufacturing Kentucky, the author tells us of her experience with standardization… and of the deep leadership lessons hiding behind it.
FEATURE – What if we ran our production schedule to time instead of quantity? While creating overproduction, running to time is a temporary first step to establish levelled production with fixed repetitive cycles.
INTERVIEW – An American group of restaurants is experimenting with the application of lean thinking in its kitchens and dining areas. Planet Lean had a word with the chefs to see what’s cooking.
NEWS - LEI partners with the Institute for Intrapreneurship to help established and startup companies to become more innovative using lean thinking and practices.
DOCUMENTARY – In PL’s first ever documentary, we share the story of a chain of car dealerships in Africa. Watch and learn how people development and lean leadership made for one of the best turnarounds you’ll ever encounter.
FEATURE – Much has been said and written about Toyota’s ability to recover from disasters. What many don’t realize, however, is that the company’s recovery strategy is informed by its underlying values – not just its tools.
INTERVIEW – Italy-based precision machinery manufacturer Sisma has changed skin many times over the years. We sat down with its general manager to learn how the firm has been able to continuously innovate over the years.
WOMACK'S YOKOTEN – On October 3, Toyota will cease its manufacturing operations in Australia, but the way it is managing the transition - in the leanest way possible - holds great lessons for us all.
FEATURE – What does levelled production have to do with product costing? This article explains how getting your accountants to understand this link can help your company become less complex, more efficient and profitable.
FEATURE – There is a form of waste – complexity in raw and packaging materials – that adds costs to manufacturing without creating value, but it is often overlooked. The author explains what it is and how to banish it.
FEATURE – A broken phone or a clock showing the wrong time may seem small details to you, but they actually make people's jobs more difficult. Fixing these issues improves work and boosts morale... It also says a lot about you as a company.
FEATURE – We often think that making every product customers might want – no matter how little they sell or how much complexity they add to our schedule – is inherently lean. As Toyota understands quite well, however, it is quite the opposite.
FEATURE – It might be widely used as a planning system, but ERP – Ian Glenday argues – is not conducive to an environment where lean thinking can thrive: because it is based on a batch logic, it always creates a different plan and, with it, instability.
INTERVIEW – Planet Lean meets LEGO’s Ilona Takács to learn how the toy manufacturer looked at its corporate values to built a new, super-lean factory in eastern Hungary.
INTERVIEW - Anton Ulanov is the CEO of one of the largest agricultural businesses in Russia. He talks with PL about the application of lean at Agroholding Kuban, discussing the wider challenges and opportunities for lean in agriculture.
INTERVIEW – In 2020, GE Appliances had to stand up a brand-new assembly process for a new dishwasher. The leader responsible for the program explains how LPPD helped them to get it right.
CASE STUDY – Starting in January this year, the Mexican plant of this manufacturer of lighting and electrical solutions has initiated a lean transformation that has already led to impressive results in terms of productivity.
FEATURE – The gemba tells us more than we think. The authors discuss what we need to look at during our walks to understand the impact of non-manufacturing functions on the overall process.
FEATURE – In the third article in his series, Christoph Roser provides a practical guide to understand the most adequate pull system to your circumstances.
FEATURE – Before you decide which method to use to establish pull, you must consider a number of factors. Here’s the things you should be paying attention to.
FEATURE – Kanban is the best-known method to establish pull production, but it is not the only one. Here’s a few other ways you can create a pull system.
FEATURE – The release of Christoph Roser’s new book All About Pull inspires John Shook to discuss the origins and true meaning of “pull” and why it is incorrect to blame JIT for the shortcomings of global supply chains.
FEATURE – What does it take to meet the historic challenge of rapidly increasing the annual global vaccine capacity from 5 billion to 19 billion doses? And how could Lean Thinking help?
FEATURE – Aligning supply flows with demand is crucial to success, but it can be complicated. Lean Thinking can help us identify the strategy and sequence of activities that we need to make it a reality.
FEATURE – This article analyzes some of the most effective tools lean practitioners can deploy to design solid processes characterized by an effective sequence of tasks and a focus on customer value.
FEATURE – Sometimes you just need to get creative: as part of its flexible manufacturing model, Esquel introduced a new role on its shop floor – the “mangineer”.
INTERVIEW – Thirty years ago, a book introduced lean thinking to the world, started a global movement and transformed business forever. Our editor caught up with one of the authors.
CASE STUDY – An Esquel factory in GuiLin, China injected lean principles and practices into its processes to become more efficient and environmentally-friendly.
FEATURE – When the number of Covid-19 cases skyrocketed in the Italian region of Piedmont, this microbiology lab had to find a way to increase its capacity to process swab tests. Here’s how they did it.
FEATURE – The Covid-19 pandemic has exposed all the shortcomings of our current supply chains. Lean Thinking can make them more agile, aligned and adaptive.
CASE STUDY – This company in Botswana has embraced lean thinking passionately to build the capacity and ability to deal with higher demand for its converted vehicles. The author tells us about their journey.
NOTES FROM THE GEMBA – By introducing flow in its processes and transforming its approach to managing the business, this French manufacturer of fences and gates is building a competitive advantage.
CASE STUDY – Thousands of kaizens, a relentless focus on learning and the determination to continuously improve have made of this Norwegian company something of a lean fairytale.
CASE STUDY – What to do when you operate in a competitive market and are located in a remote corner of Europe, thousands of miles from your customer? One word: lean.
FEATURE – By leveraging lean product and process development principles, Nichirin Spain is becoming more flexible managing last-minute changes in product design requested by customers.
CASE STUDY – A Turkish producer of gas valves for kitchen appliances has discovered the power of the lean principles of pull and flow, reaching results beyond its imagination.
PROFILE – What does one learn from working for Toyota over 40 years? This Australian leader has developed a unique holistic view, and a strong set of technical and social skills.
THE LEAN BAKERY – In this episode of our video series, we visit 365's super-lean workshop, where small batches and a clever use of space allow for unprecedented levels of flexibility in manufacture.
INTERVIEW – Ben Hartman has used lean in his micro-farm in Indiana for six years. Not only did he find in it a way to support his family doing what he loves, he might have also discovered how to transform our food system.
THE LEAN BAKERY – In the second video in the series, we visit the stock-free workshop of one of 365's lean bakeries and learn about quality bread, customer focus and making lives easier for bakers.
NOTES FROM THE GEMBA – This month, the author shares her account of a recent gemba walk at a Tier 2 Toyota supplier, which has achieved impressive results by applying TPS.
CASE STUDY – Faced with complex logistics and customer complaints, a small deli and butchery in Botswana saw in lean a way to bring the business back from the brink. The philosophy didn’t fail them.
FEATURE – You have never seen a workshop like this before: Halfway Ngami in Botswana has creatively transformed car servicing and repairs by making problems visible and introducing flow.
FEATURE – Designing beautiful work helps design beautiful clothes. Here’s the story of how women’s clothing brand Eileen Fisher found in lean a way to support its environmental sustainability strategy.
NOTES FROM THE GEMBA – Follow Catherine on another one of her gemba walks around French companies. This time, she visits a manufacturer of inspecting machines near Bordeaux, with a visionary leader and a great story.
FEATURE – In the final article of his series on levelled production, the author debunks the belief that the Glenday Sieve is a method that can only be used in a manufacturing environment.
FEATURE – When they realized their lean efforts had overlooked the crucial aspect of management behavior, AkzoNobel senior leaders turned to a great lean book for help with leadership development.
FEATURE – If we have high-volume (green) and low-volume (red) items in our production schedule, doesn’t it make sense to also have dedicated green and red equipment whenever possible?
FEATURE – In the latest article in his series on how to effectively level production, Ian Glenday discusses why the perceived high variability of our demand is actually the result of a misconception… think about it in percentage terms!
FEATURE – In the latest article of his series for Planet Lean, Ian Glenday explains the practical steps an organization can take to properly introduce levelled production in its operations.
FEATURE – Repeating the same patterns of work over six to eight cycles of production generates improvements - based on people, not machines - and facilitates the adoption of lean principles and tools.
FEATURE - The original TPS "house" had levelled production at its foundation because Toyota understood that establishing and sustaining continuous improvement is impossible without creating stability in production first. What about your transformation?
FEATURE – Repetitive flexible supply is a very effective method to level production scheduling, but as a FMCG company in the Netherlands found out, sometimes a number of conditions must be met before the approach becomes viable.
FEATURE – Does lean management help us at strategic level as much as it does operationally? What’s the strategic thinking behind lean thinking? Michael Ballé answers these questions by looking back at some of history’s great military strategists.
CASE STUDY - An approach based on Lean Daily Management System and experiments in a model area led an Italian manufacturer of combine-harvesters to become one of the leanest organizations in the Veneto region.
CASE STUDY - Össur is recognized as a leader in the fields of prosthetic, osteoarthritis and injury solutions, but how did lean management and a trial-and-error approach to improvement help it to stay competitive?
INTERVIEW - The General Manager of a Delphi plant in Hungary talks about the lean transformation the site went through and the challenges automotive suppliers face in this day and age.
FEATURE – Effectively applying just-in-time and achieving flow is impossible without leveling production first. Yet, most companies seem to think this is impossible because demand is so variable… but is it really?
FEATURE - The author looks back at his many years with Toyota and shares some of the key lessons he learned along the way. What a unique company!
