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Andon System (行灯 - システム) – The Real Visual Management tool.
I have studied many Visual Management Deployments on several manufacturing factories, and I have found a big misunderstanding of Visual Management tool, this have called my attention on the last days...
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Pitch and Heijunka (ピッチと平準化) – Part 1 of 2
Pitch at the Pace maker Definition of Pitch / Mizusumashi Cycle• Pitch refers to how often we release and take away work from the pacemaker• The amount of time needed in a production...
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Pitch and Heijunka (ピッチと平準化) – Part 2 of 2.
Heijunka Concept. No mass production system can be continuously responsive to gyrating orders without suffering from muri (overburden of machines, managers, and production associates), and mura...
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Zero Defects (無欠陥) – Part 1 of 3 - Five Elements of Production and the Five...
This article is intended to describe the sequence for Root Cause analysis, from the point of view of Sensei Shigeo Shingo and is based on my own experiences as an instructor of TPS continuous...
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Zero Defects (無欠陥)– Part 2 of 3- San-Gen-Shugi methodology (Genba ,Genbutsu &...
I have considered to describe on this article the San-Gen-Shugi methodology, which underlies the breakthrough approach for Problem Solving.San-Gen-Shugi – Genba ,Genbutsu & Genjitsu.San (three),...
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Zero Defects (無欠陥) – Part 3 of 3 Using Poka-Yoke (ポカヨケ) System
This is the third part of the article Zero Defects, and I have chosen the theme of pokayoke system, focused on the use of devices that are required to build a Pokayoke.In my experience as a consultant,...
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3P Production Preparation Process - (生産、準備、プロセス)
Many people asked me why some companies fails on Lean Enterprise implementation? Obviously there are many reason why to fail, however, the companies that embrace Lean Manufacturing and implement the 3P...
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Standard Work and the PDCA cycle.
I love teach Standard Work to young Engineers, their expectations are always what type of software I going to show, and they look very confused when I say “ dear Team to day I’ll teach all of you to...
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Kaizen Events and the Ideas Generator “TRIZ” - The way to generate creativity...
On kaizen Events the Teams must come up with solutions for the problems exposed on VSM, after set the targets and scope of the loop you want to fix; this must happen within a period of time of 5 days;...
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Lean implementation; that generates Benefits for the real Bottom Line P&L and...
As Lean Manufacturing consultant it’s very important for me; provide services and results to my customers; tangibles to P&L and Balance Sheet (Cash Flow).I have found that in many organizations,...
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Kaizen Teian: The Ideas are worthless if they are not implemented; this is...
I have visited some organizations that have implemented the Employee Suggestions System, but many of them have not obtained the benefits of this system directly reflected on P&L , and when I have...
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Kaikaku カイカク- Steps “Radical Improvement or Change”.
As consultant, I have recommended to my customer different approaches or methods to reach the Lean Manufacturing Benefits as soon as possible, and in some special situation I have run a Kaikaku event...
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How to depict, many processes flows at one VSM current state? And How...
After my previous blog publication about “How to depict the Inventory or the Process Cycle Times on VSM when those are in parallel? The right way….”...
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Therbligs Motion Analysis, the next Step after Standard Work.
I teach the Therbligs Motion Analysis (TMA) to my customers, just after done the first improvement (Standard Work) on the process or manufacturing line or cell, the reason is very simple, after the...
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Avoiding the “Blind Genba Walks” to help the Management Staff- (Buraindo...
I have had the opportunity to learn many different things, of Japanese Senseis; tools, methods, and culture change behaviors etc.However; avoid the “Blind Genba Walks” is one of the best methods I...
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Obeya “War Room” a powerful Visual Management Tool.
On Toyota Management System there is one Visual Tool that helps the teams to reach the Goals and promotes generations of solutionsandactions; thatcanbedevelopedandimplementedquickly. This tool is known...
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Takt Time vs Manual Cycle Time: The method to calculate the Quantity of...
This article was written based on my experience as consultant.After many Kaizen event I have found there is 2 misunderstandings about how calculate the Number of Operators that are needed to run a...
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“Takt Time” For a Warehouse – Lean Supply Chain Kaizen
To calculate Takt Time in manufacturing, you divide available production time by the number of products to be made (Customer demand), which tells you the time available to make one product (The Rhythm...
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The 7+1 Mudas (wastes) – For Office, Manufacturing and Supply Chain.
Many people ask me about examples of Mudas (wastes) on 3 main categories, Manufacturing, Office and Supply Chain; for that reason I always share the next table with my customers.The table do not cover...
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KPO team Members and the Lean Implementation Change curve.
Many customers ask my help to define the KPO (Kaizen Promotion Offices) or Lean Manufacturing Department, some concerns are related to People Characteristics, Aptitudes and Attitudes.My first advice...
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