lean manufacturing

Lean in internal supply logistics

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Case studiesJul 9, 2020
Alvair Silveira Torres Jr.
CASE STUDY – The implementation of lean in the internal logistics of a pharmaceutical company in Brazil proved key to increasing productivity and quality in the organization.

Four types of problems, in the management system

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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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FeaturesJul 2, 2020
Gustavo Adolfo Gomez Pineda
FEATURE – A lean management system is necessary to effectively run a business. Can Art Smalley’s four types of problems framework help such a system to focus on what’s really important?

Facing the crisis with an appetite for improvement

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FeaturesMay 6, 2020
Catherine Chabiron
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.

Lean thinking for more resilient supply chains

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FeaturesMay 4, 2020
Alvair Silveira Torres Jr.
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.

Facing the emergency

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FeaturesApr 1, 2020
Catherine Chabiron
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.

Harada-san and the steps to better Jidoka

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FeaturesMar 23, 2020
Toshiko Narusawa, Joe Lee and John Shook
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.

Immunity

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Case studiesMar 19, 2020
Sergio Ferigo, Gianni Lorenzani and Matteo Consagra
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.

Learning to be lean chameleons

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FeaturesFeb 13, 2020
Teri Laeder
FEATURE – In this candid, personal account, the author shares her experience as a lean coach, her challenges and success, and how she adapts to different situations.

Half the bad, double the good

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Case studiesJan 20, 2020
Eivind Reke and Kenneth Gilje
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.

Centerlining: what it is and how it works

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FeaturesJan 16, 2020
Severino Abad
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.

A lean transformation is a cognitive transformation

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FeaturesNov 25, 2019
Eivind Reke, Robert Kusén & Daryl Powell
FEATURE – By looking at two practical examples, the authors discuss the cognitive shift towards learning and continuous improvement that takes place in a lean transformation.

The gateway to success

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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.

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FeaturesNov 11, 2019
Catherine Chabiron
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.

Kaizen all around

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FeaturesNov 4, 2019
Francesca Tiraboschi and Matteo Farina
FEATURE – Two coaches from Italian company FPZ reflect on their role helping lean thinking spread across the company and its newly-acquired businesses.

Lean-n-food

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FeaturesOct 21, 2019
Josh Howell
FEATURE – The food industry is mired with problems all along the value chain. In this call to arms, the author explains why lean thinking is the only tool we have to transform it right now.

A journey of mind-blowing improvement

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Case studiesOct 3, 2019
Sergio Ferigo
CASE STUDY – Seven years ago, this Italian manufacturer ran an experiment to reduce inventory in its warehouse. Today, lean thinking permeates every aspect of life at FPZ.

Leadership development at Volvo Cars

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Case studiesSep 16, 2019
Eivind Reke and Gert Frick
CASE STUDY – What is the approach to people development used at Volvo Cars? The authors explain how the organization has created a production system fully owned by operators and managers.

A sense of heritage in an uncertain world

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FeaturesJul 30, 2019
Catherine Chabiron
FEATURE – In a market where products become obsolete very fast, this Toyota supplier has learned the importance of staying true to its heritage and developing know-how and people’s capabilities.

Cancelling the distance

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Case studiesJul 16, 2019
José Ignacio Garcia Cornejo and Francisco Soler Benito
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.