Kaizen and the Visual Workplace

Two additional sections of our lean manufacturing suite of web sites have come online.

Kaizen - visit this site to learn about kaizen, what it is and the benefits of kaizen. Test your knowledge of kaizen using the free, online Kaizen Quiz.

Visual Workplace - a basic component of all lean methods is visual communication, which results in a visual workplace. Visual communication is the use of labels and signs to communicate information at the point of need, when it is needed. This includes OSHA required safety signs as well as non-required, but still essential labels that identify equipment, and provide operating and maintenance information.

7,500 man hours to 3,600 - Saving with Kaizen

I found a nice article at GrandsForksHerald.com about the often amazing benefits of a full lean implementation.

While the majority of the article concerns LM, this passage about Cirrus Design really stood out to me -

"Coincidentally, Cirrus Design, a neighboring plant in the Industrial Park, went through a similar process back in 2001. The company found its workforce was just too inefficient, preventing it from building airplanes as fast as it wanted. In came the Toyota Production System, also known as lean manufacturing.
Like kaizen, it emphasized continuous elimination of waste and inefficiency. Within just three months, Cirrus Design reduced the number of worker-hours needed to build a plane from 7,500 to 3,600. "

Let's ignore the little mix-up concerning kaizen, lean and TPM and look at those figures.
7,500 worker-hours.
3,600 worker-hours.

Labor hours were more than halved through the implementation of Lean Manufacturing.
Alternatively, one could say efficiency more than doubled!

That's mind blowing.
That's kaizen, that's kanban, that's lean.

We've repeatedly seen that the benefits of lean manufacturing can be found in almost any field. How many times do you have to see figures like this or watch companies like LM succeed before you implement lean?

Lean Manufacturing meet the Lean Web

Perhaps I missed the boat on this one, but I had no idea internet giants like Ebay had dedicated lean departments.

Ahem. "Process Improvement for Customer Service" departments.

I find this out through the news that Peter Abilla, author of the shmula blog and a fellow U of C graduate, will be speaking at the Lean Six Sigma Summit.

A quick glance through the speakers gives a powerful testament to the advantages of adapting lean - Ebay, United Airlines, Walt Disney World Resort, Wells Fargo.

Companies from all walks of business are dedicated to lean - to the point that they have in house experts ready and willing to spread the word. Lean is coming, it can save you money.
Just ask Xerox, or Johnson & Johnson, or Countrywide Financial, or Tyco International, or ...

The visual organization of space, the implementation of kaizen, the use of a kanban system - these tools are used by some of the biggest and best companies in the world, why not yours?

Another Lean Adopter

This time it's New England Peptide, a company who, unsurprisingly, produces peptides and antibodies based in New England.

Peptide "manufacturing" is clearly not one of the areas traditionally associated with lean, but that hasn't stopped NEP from reaping its benefits.

According to a recent press release NEP can improve its lead time by 25% in 12 to 18 months. For a company already with the best lead time in its industry, this increase can only boost customer satisfaction and worker productivity.

Using techniques like 5s, NEP's founder feels they are bringing a "new level of sophistication" to the business.

The visual organization of space can seriously improve lead time - it turns out in almost any industry!

Quick Article Posting

Nice read on lean adoption not having to mean "layoffs" over on the Worcester Business Journal.

With a $50,000 dollar grant, a multi-million dollar corporation was able to enact and sustain a full Lean makeover - saving an estimated $8.2 million over the past five years.

That's not a terrible investment by any means.

How was it possible?
Only with the "trust and full participation of its employees."

This is why making lean not another coded word for a round of layoffs is so critical. It's success hinges upon employee buy-in.

FLEXcon appears to have done it in a slightly unusual way - they educated their entire work force on lean from the get go. Bringing everyone in up front isn't always practiced, but it certainly seems to have worked here.

The Meaning of 5S

I write a lot about 5s, both in this blog and for my company. We get a lot of business from people interested in how labels can support, create and maintain the visual workspace.

But when is something a true 5S implementation and when is it just good business sense?
Take for example those wondrous little guide lights in parking garages - you know, the ones that tell you how many spaces are available in each row/section of the garage, saving both time and hassle.

They certainly visually organize the environment, they keep it clean and well organized and they sustain this organization.

But is it a true 5S implementation?

Pehsk's blog has a recent post maintaining that it is.

I can certainly see how it contains elements of 5S, and I can see how it benefits the garage and the consumer. I can also see how it empowers the individual user (in this case a driver) to make an informed decision about where to drive.

Take a look at some of his photos, and let me know what you think?
Is it lean, is it 5S - or is it just good solid business sense?
Is there a difference?

... And does it matter?

New Kanban Web Site With Online Kanban Quiz

Our Introduction to Kanban web site went online today.

This new web site is designed to answer the questions: What is kanban and what are the benefits of kanban? It provides an overview of kanban that helps those new to lean manufacturing techniques to quickly understand what kanban can do.

As with our new 5S web site, the kanban web site includes a Kanban Quiz. This short quiz is a fun way to test your kanban knowledge and compare yourself with others who have taken the quiz.

We also offer a printed guide to Kanban. This 24 page booklet provides a complete overview of kanban, including information about implementing kanban.

New 5S Web Site & 5S Quiz

Our 5S web site is now available.

Serving as an introduction to 5S, this web site provides a concise overview of 5S and its benefits.

What's unique about this web site is that it offers a free, online 5S quiz. The 5S quiz is a fun way to test your 5S knowledge and compare yourself with others who have taken the quiz.

We also offer two printed 5S guides. Our "Introduction To 5S" is a 12 page booklet that provides a complete overview of the basic information about 5S. The "5S Standard Color Code Guide" is a laminated chart that shows the code code scheme that has become the defacto standard for 5S color coding. Both guides are available free and may be requested using a form on our new 5S web site.