Thursday, April 19, 2007

Example of change to one-piece flow

Example of a change from batch production to one-piece flow
Last week I observed a change from batch production to one-piece flow in a local factory. I will write more about this later…

Remember: One-piece flow is not always in one piece!
It is important to notice, that the phrase “one-piece” is not necessarely referring to the fact that products are moving piece by piece. Often it does make sence to accept a small buffer between processes. This often depends on the value of the products.

Make one-piece flow that addapts to real life
Just remember to use common sense when implementering flow and one-piece.
Think of things like

  • Time for operators to have a short brake - e.g. toilet
  • Is the quality of the product unknown or known - if you know that the Q is good buffer is more accepted

Friday, March 9, 2007

What is Lean Administration?

Lean Administration is all about creating value with minimum effort!
Lean Administration is all about creating value in the administrative value stream. Lean Administration is the heading for a list of tools to work with Lean in your administrative activities. Mainly the tools helps you to indentify the value stream and to minimize/eliminate the waste found in this value stream. The tools are all closely linked to the
five Lean principles.
The tools can be used in any kind of administrative flow. In these flows you will always find waiting, rework due to bad quality, stocks seen as overloaded mailboxes or files, change in responsibility and missing standard work. Non of these create value to your customers.
Possible results using Lean in your administration:- Improved customer service- More simple and visible flow- Reduced waste (in Lean = Muda) and less rework- Improve throughput time- Etc.

Sunday, January 21, 2007

Implementation of Lean Manufacturing takes time

My experience when implementing Lean seen from a strategic point of view is, that there are four main phases:
  1. The strategic decision.
  2. Ensure the basis for Lean changes.
  3. Continous Improvements.
  4. Maintain the gained level and extend the value stream.
Article will be finished soon! So come back!

Saturday, October 28, 2006

The 5 Lean Principles

Lean is all about creating the right value for customers with minimum effort!

The 5 Lean principles are:

  1. Define value seen from the customers/markets point of view.
  2. Identify the value stream (activities) that delivers the value defined in point 1.
  3. Create flow in the value stream.
  4. Create pull (order driven) in the value stream.
  5. Create a culture of continuous improvement (Kaizen) in the organisation.

The principles in short:

Principle 1: Customer value

Lean Thinking is all about delivering the value demanded by the customers. No more. No less.
The principle applies not only to the physical product. It also applies to service, logistics, information etc.
The principle of ”customer value” permeates a Lean organization.

Principle 2: Define the value stream

When the value has been defined, the value stream that creates the value must be identified and optimized.
The value stream is mapped and optimized step by step.
The target is to minimize waste.

Principle 3: Create flow

The most powerful tool to minimize waste in the value stream is flow.
The value for the customer should be created in a flow of activities and processes.
Flow with a minimum of unnecessary stops in the steps.
Flow gives significant results.

Principle 4: Create pull

Among other things, the target with flow is to minimize the through put time of a value stream, so that most activities and processes are based on firm customer orders and not forecasting.
Principle no. 4 is about carrying out as many steps as possible in the value stream based on customer demand.

Principle 5: Continuous improvement

Principle no. 5 is to create a culture of continuous improvement.
It is more about culture and attitudes than management Lean-tools.
The organization should continuously strive to become better. Every day.
Continuous improvement is also known as ”Kaizen” (Japanese).

By Mikkel Smith
Flexkom - download Lean tools online >
Scandinavian website with Lean courses >

Sunday, July 9, 2006

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