lean process

Inventory reduction and pulled supply in a Brazilian factory

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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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FeaturesNov 9, 2017

Ricardo Avila, Douglas Agassi & Alexandre Cardoso

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.

Kaizen and improved maintenance in a Turkish mine

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Case studiesNov 7, 2017

Selçuk Turan & Hüsrev Yaman

CASE STUDY – Over the past four years, by developing its kaizen capabilities and crafting a better approach to maintenance, a Turkish gold mine has significantly reduced its extraction costs.

Growing car sales by 400% in a dealership using lean

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A common problem that practitioners trying to bring lean to services encounter is the difficulty to identify “the work” – whereas in manufacturing the product is in front of everyone’s eyes, in service organizations it is often hidden behind paperwork or a computer screen. Once the work is clearly visible, however, the opportunities for improvement are plentiful. To date, we have seen thousands of organizations striving to lean out the service they provide customers: from restaurants chains in the United States and China to a group of bakeries in Barcelona, from call centers to hotels, the application of lean services ideas can have an extraordinary impact on our economies. Especially if we consider that the service industry accounts for more than three-fifths of the global GDP and employs more than one-third of the global workforce.

Lean thinking is naturally a fit for the service industry, because of its focus on constantly delighting customers and on providing them with value-adding products."
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FeaturesOct 4, 2017

Calvin Govender, Charmaine Lategan & Dale Thomas

FEATURE – For the first article in our series on the Halfway transformation, we asked the Sales team to tell us about how they apply lean to selling cars in a challenging social context.

How lean coaching changed the culture of a restaurant chain

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FeaturesAug 23, 2017

Jeff Zhou

FEATURE – An approach based on coaching and experiments is transforming the way restaurant chain Xibei works with its people to improve service and dishes: the story of Chef Liang and his Kongfu fish.

Lean and sustainable fashion meet at Eileen Fisher

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FeaturesJul 6, 2017

Johanne Read and Tess De Mesa with Alice Lee

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.

Adopting lean principles to speed up blood donation

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FeaturesMar 10, 2017

Morena Venturini & Francesca Marchi

FEATURE – In the second article of our series written by the front-line staff of Siena University Hospital, we learn how the lean principles of pull and flow have transformed the blood donating process.

The first steps of a Paris hospital towards lean healthcare

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FeaturesJan 13, 2017

Catherine Chabiron

NOTES FROM THE GEMBA – On this gemba walk in the cardiology department of a Parisian hospital, the author discovers how the team is changing its internal dynamics and processes to make lean their way of thinking.

Dedicated green and red equipment for different products

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FeaturesJan 11, 2017

Ian Glenday

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?

Eliminate complexity in raw and packaging materials

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FeaturesNov 9, 2016

Ian Glenday

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.

The Wells Fargo scandal teaches us lean must be nurtured

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Opinion piecesOct 28, 2016

Boaz Tamir

OPINION – The latest banking scandal had us all wonder whether Wells Fargo has lost its way. But how does a pioneering bank that once had lean at its heart betray its core values so profoundly?

The community comments on the Lean Thinking book

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FeaturesSep 19, 2016

Planet Lean

FEATURE – It’s Lean Thinking week and to commemorate the 20th anniversary of the publication of the book, we have asked a few people from the lean community what it meant to them.

Ballé: before others, lean experts should heal themselves

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FeaturesAug 1, 2016

Michael Ballé

FEATURE – The role of experts in lean thinking is often the subject of heated discussions. Here, Michael Ballé tells us about the common mistakes lean experts make, and explains why – before helping others – they should help themselves.

Meet a champion of Catalonia’s lean healthcare movement

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ProfilesJul 14, 2016

Roberto Priolo

PROFILE – Lean is spreading like wildfire across the Catalonian healthcare sector, following a do-it-yourself model unique to this part of the world. Our editor met one of the practitioners who are making it happen.

Polyglot and TPS student – a profile of Toyota Europe’s CIO

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ProfilesJun 14, 2016

Roberto Priolo

PROFILE – A commitment to learning and the humility to understand we never really know enough have led a Belgian mathematician to become a polyglot… and the CIO of Toyota Motor Europe.

A gemba story to study lean thinking in construction

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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.

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