The 19 billion doses challenge
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?
Lean Manufacturing
Manufacturing is where the lean movement originated from. For their MIT research in the late 1980s (which resulted in the 1990 seminal book The Machine the Changed the World), Jim Womack and Dan Jones identified a set of principles and techniques that made Japanese carmakers far more productive than their Western competitors.
The superiority of the Toyota Production System is now a recognized fact (Toyota has been profitable every year but one, for half a century), which means that today most manufacturing organizations around the world practice lean manufacturing thinking to some extent. The prevalence of this alternative way of thinking and managing in the manufacturing sector often generates confusion in other industries, in which people’s first reaction to improvement attempts is the now proverbial “We don’t make cars. Lean is a manufacturing thing.”
When applied to manufacturing, lean tools like heijunka, SMED or Kanban cards allow for the optimization of production processes and the systematic elimination of waste (in its three incarnations of muda, muri and mura – respectively, non-value-adding work, overburden and unevenness). These happen by implementing the fundamental lean principles of pull and flow. However, it has now been proved that the principles characterizing lean manufacturing are universally applicable. They work in any sector and they apply to any kind of work – even though at times they require some adjustment.
Kamishibai for better conversations at the gemba
FEATURE – How do kamishibai boards work and what sort of benefits can they bring to a lean transformation? The author discusses what he saw on a recent gemba walk.
Creating front-line leaders to solve problems at Nestlé
INTERVIEW – In this Q&A, we learn how the Technical & Production (T&P) area of Nestlé Colombia Ecuador is using lean and Art Smalley’s four types of problems framework to bring leadership closer to the gemba.
‘Steel’ going strong
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.
The J-Cost theory
FEATURE – The approach described here, first adopted by this Chinese company, directly connects the daily work in manufacturing with an organization’s financial results.
The synchronization of material flow with demand
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.
Lean ASAP!
CASE STUDY – Some have 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 front-line healthcare workers.
The “mangineer” and people development
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”.
30 years since Machine came out – Part 1
INTERVIEW – In the fall of 1990, a book was published that would kickstart a revolution in business. This week we are catching up with the authors to understand where we are and where we are headed. First up, Daniel Jones.
Smooth as silk
CASE STUDY – An Esquel factory in GuiLin, China injected lean principles and practices into its processes to become more efficient and environmentally-friendly.
Changing our minds to change our business
NOTES FROM THE GEMBA – It can take time to challenge our misconceptions and set off on a lean journey. Once we get it, however, it’s hard to stop the improvements, as this French company found out.
Facing the crisis with an appetite for improvement
NOTES FROM THE VIRTUAL GEMBA – Despite a 40% drop in sales and the looming prospect of having to furlough part of its staff, this French company is finding in lean manufacturing an ally to fight the current crisis.
Learning fast in the crisis
NOTES FROM THE (VIRTUAL) GEMBA – This small manufacturer is relying on Lean Thinking to keep the business running during the Covid-19 crisis, overcome the disruption in its supply chain, and even innovate.
Facing the emergency
NOTES FROM THE (VIRTUAL) GEMBA – In this new series - one new article every week during the Covid-19 crisis) - the author asks companies how they are reacting to this health emergency. First up, Proditec.
Immunity
CASE STUDY – This Italian manufacturer has found in lean a way to ensure business continuity and provide support to a distraught workforce in the midst of the coronavirus outbreak.
Half the bad, double the good
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.
Bringing lean to the people
CASE STUDY – This article briefly outlines the different stages of the lean transformation at Mercedes Benz Brazil, as the company looked for the best approach to engage everyone in continuous improvement.
The gateway to success
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.