lean for competitiveness

Three key business challenges lean can tackle

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FeaturesMay 7, 2019
Tomasz Koch and Remigiusz Horbal
FEATURE – Ahead of the annual lean conference of LEI Polska, the authors reflect on a recent survey they ran with their clients on the key business challenges they face.

Surviving an inflection point

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FeaturesApr 9, 2019
Jim Morgan
FEATURE – The car industry is undergoing incredible change and ‘disruption’ is the word on everyone’s lips. How can companies survive it? Once again, Toyota shows us the way.

Lean caters for our product development needs

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At its core, Lean Product and Process Development aims to create the exact product that people want. And it is clear that developing better products reaching the market faster means profitability into the future. In general terms, lean product development achieves this by creating reusable knowledge that can be used in future iterations of a product and by deployment set-based concurrent engineering (which entails considering sets of designs at once to quickly eliminate inferior solutions, thus shortening development times). It is also useful to integrate the work of engineers with that of the manufacturing department, so that shop floor receives a well-researched, mistake-proof product that is ready for production without the need for extensive and expensive rework.

Interesting contamination exists here with improvement approaches like Lean Startup and Design for Manufacturing."
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FeaturesMar 19, 2019
Catherine Chabiron
NOTES FROM THE GEMBA – This French company has completely transformed its approach to designing and introducing new products to market by embracing lean product development ideas.

Lean as a two-step engine

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    string(1378) "The idea of “lean management” can refer to both individual managerial behaviors and, more in general, the set of principles and practices characterizing the adoption of lean thinking in an organization.

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FeaturesMar 14, 2019
Michael Ballé & Nicolas Chartier
FEATURE – One of the things making lean thinking so hard to explain in general terms is its dual nature as both an organizational and managerial approach. The authors explain how to handle this tension.

Lean thinker, I salute thee

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FeaturesDec 27, 2018
Roberto Priolo
ROUND-UP – As the year ends, our editor reflects on the state of the lean movement and looks back at the best articles published by Planet Lean this year.

Quality by kaikaku

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    string(1594) "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."
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    string(1593) "The term “lean production” refers to the set of tools and techniques used to streamline and improve a company’s production system. With its roots in the Toyota Production System, lean production aims to boost productivity while reducing waste. Companies that successfully embrace lean production methods can achieve impressive improvements in their performance. The superiority of a lean production system was first identified by Womack and Jones during their research on Japanese carmakers. Initially, it was believed that lean was only applicable to production, whereas today we know those principles can be applied in any sector.

With more and more organizations (not just manufacturing firms) turning to automation to try and solve every-day problems, lean production offers an approach that gives the operators and their work the dignity they deserve. This idea is best expressed by the concept of the andon, a cord hanging above lean production lines that operators can pull whenever they encounter a problem they can’t solve right way (this is the base of the fundamental lean principles of jidoka, “automation with a human touch”). Lean is clearly an alternative to reckless management that considers people as mere capital.

The main characteristics of a lean production system are the fact the different stages of production happen in a sequence without interruptions (known as flow) and that the pace of production is set by the customers (pull)."
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Case studiesDec 13, 2018
Tayfun Goksen
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.

Where the true strength of an obeya lies

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FeaturesDec 4, 2018
Régis Medina and Sandrine Olivencia
FEATURE – The obeya room limits the number of unknowns before we start developing a product. In this sense, it’s a tool for discovery more than it is for delivery.
strategy for success Boaz Tamir

Boaz Tamir on why success does not come down to chance

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ColumnsSep 7, 2017
Boaz Tamir
OPINION – The rise and fall of organizations does not depend on chance or bad luck. It generally stems from a fundamentally flawed strategic approach that fails to define a purpose, alienates workers and ignores customers.
managing for the future lean thinking

Lean as the management strategy of the future

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    string(1378) "The idea of “lean management” can refer to both individual managerial behaviors and, more in general, the set of principles and practices characterizing the adoption of lean thinking in an organization.

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FeaturesAug 25, 2017
Dan Jones
FEATURE – Lean is a people-centric system for learning that acts as an alternative to traditional management and financial capitalism. It represents the best strategy a company can adopt to meet the needs of the future.
gemba walk Paris Ouest Construction

How a construction company survived the recession using lean

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The lean construction movement soon spread to other parts of the world, starting with the UK - where it influenced a number of organizations and large projects, like the construction of St Pancras station in London. Large construction companies quickly took on lean management. Like in other industries, at the beginning the adoption of lean focused heavily on the application of tools, whereas more recently the strategic importance of lean management has been recognized by the industry.

Technology is providing new opportunities for the sector, with 3D and 4D software tools taking the lead. Technological advances, coupled with the adoption of solid improvement practices, like lean construction methodology, in the construction industry, means we can design and build better, safer and lasting buildings - also guaranteeing working infrastructure for our increasingly urban world."
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FeaturesJun 16, 2017
Catherine Chabiron
NOTES FROM THE GEMBA – With a strong focus on quality and on solving problems once and for all, Paris Ouest Construction has managed to weather the storm of the recession, the author finds out during a gemba walk.
Gemba walk Alliance Chabiron

People development and competitivess – the Alliance story

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FeaturesMay 15, 2017
Catherine Chabiron
NOTES FROM THE GEMBA – This month, Catherine visits a metal injection moulding specialist and hears about the strong link between growing people’s capabilities with lean thinking and staying competitive in a complex market.
customer service digital world

In the digital world customer service alone is not enough

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FeaturesFeb 22, 2017
Steve Bell & Karen Whitley Bell
FEATURE – As many retail giants are finding out, great customer service is no longer enough to ensure competitive advantage in a world where the digital revolution is taking no prisoners.
challenges banking lean it

Without lean IT our banks have no way to fight competition

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FeaturesJan 23, 2017
Marie-Pia Ignace
FEATURE – The banking sector is floundering in the face of heavy regulation and increased competition from fintechs. So what can banks do? The author suggests they embrace lean IT in order to change their ways.
lean accounting orry fiume

Lean accounting: a few key lessons from Wiremold

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InterviewsSep 12, 2016
Orry Fiume
INTERVIEW – In this interview, the former CFO of uber-lean company Wiremold explains why our finance people hold the key to our transformation and gives us the lowdown on lean accounting.
lean in myanmar

Lean project boosts sustainable development in Myanmar

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FeaturesSep 1, 2016
Monica Rossi & Rossella Luglietti & Giulia Donnici & Moung Kee Aung
FEATURE – A group of Italian researchers and professionals partnered with a NGO to prove how lean thinking can pave the way for the competitiveness and sustainable development of SMEs in Myanmar. Is this a new model for the developing world?
lean thinking in mining

Lean is creating a 900-strong CI team in a gold mine

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    string(1378) "The idea of “lean management” can refer to both individual managerial behaviors and, more in general, the set of principles and practices characterizing the adoption of lean thinking in an organization.

In the first case, lean management is closer in meaning to the idea of “lean leadership” and entails the development of behaviors that foster continuous improvement at the front line, such as respect for people, asking questions (rather than providing answers), going to see to really understand the work and the causes of problems, and scientific problem solving. In the second instance, lean management describes the lean philosophy more in general.

In its more general meaning, lean management – or lean thinking, if you prefer – derives from the Toyota Production System and is now recognized as a superior management approach that, through continuous improvement, customer focus, teamwork and relentless people engagement, leads to great results in terms of quality, performance, delivery, and cost. The promise of lean management is to create the most value for customers using the least possible amount of resources. As an approach to running a business, it brings benefits to all parties involved, from customers to employees, suppliers to wider society.

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Case studiesMay 9, 2016
Deanna Hall, Vicente Ramirez & Frank Wagener
CASE STUDY – The extraordinary transformation of Kinross' Round Mountain gold mine in Nevada over the past six years shows that lean thinking can – quite literally – move mountains.
lean construction gemba story

A gemba story to study lean thinking in construction

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    string(1440) "The construction industry has a reputation for delays, bad quality and unsafe working conditions. This makes it a prime candidate for the implementation of lean principles and techniques. The idea of 'lean construction' has been around since the early 1990s, when a group of academics in California started to look at opportunities for the application of lean in the sector. One of the results of this early work was the introduction of the Last Planner System to better manage construction sites.

The lean construction movement soon spread to other parts of the world, starting with the UK - where it influenced a number of organizations and large projects, like the construction of St Pancras station in London. Large construction companies quickly took on lean management. Like in other industries, at the beginning the adoption of lean focused heavily on the application of tools, whereas more recently the strategic importance of lean management has been recognized by the industry.

Technology is providing new opportunities for the sector, with 3D and 4D software tools taking the lead. Technological advances, coupled with the adoption of solid improvement practices, like lean construction methodology, in the construction industry, means we can design and build better, safer and lasting buildings - also guaranteeing working infrastructure for our increasingly urban world."
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FeaturesApr 27, 2016
John Bouthillon
INDUSTRY FOCUS – Drawing from his direct experience at the gemba, the author shares what he learned about applying lean thinking to his family’s construction company, and a few useful tips.

Why lean thinking can boost the loyalty of our customer base

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Opinion piecesApr 15, 2016
Boaz Tamir
OPINION – Most organizations today can only dream of receiving the type of enthusiastic support that certain sports teams get from their fans. In order to do that, they need to forget short-termism and put their customers first.