Whether you are implementing lean manufacturing techniques for the first time, or you are beginning a new project and you need help with lean manufacturing implementation, it is important to get it right from the very beginning. In many instances, if you don’t get the first few steps done correctly, the rest of the implementation won’t be able to be properly completed either. With this in mind,…
When we talk about continuous improvement—sometimes referred to by the Japanese term kaizen—we often discuss it in the context of the workplace. We think about ways that process such as assembling parts, organizing the workspace, or communicating with coworkers can be improved. An article in this month’s issue of the New Yorker titled “Getting Better at Getting Better” examines the way that many parts of our lives, not…
Improving and Implementing Safety Lean Manufacturing When people look at facility improvement opportunities they often look at process improvement methodologies, such as Lean Manufacturing. Another thing that is commonly reviewed is facility safety improvements. In many cases, however, they don’t see that using lean manufacturing techniques can often also provide safety improvements. Thinking about safety lean manufacturing will allow you to make improvements throughout your facility in…
A recent article at EHS Today explains how a Toyota plant that manufactures forklifts in Columbus, Ind., makes safety a part of daily life. The facility refers to its safety system as K-HYP, which standards for “kaizen” (continuous improvement) and “How’s your process?” At the facility, safety is a topic of discussion at morning meetings, and each employee is given the opportunity to write down safety issues. Then…
Most people are familiar with the normal Six Sigma methodologies that are used to help make improvements to products or services within a facility. In fact, the standard Six Sigma process has become the industry best practice for most process or product improvements. When you are creating a new product, however, the standard Six Sigma process just doesn’t work. This is why the Design for Six Sigma,…
The Right Lean Tools for Manufacturing Lean manufacturing has been growing in popularity for quite some time now. While every facility implements it slightly differently, they can all benefit from having the right lean tools for manufacturing. Look at the following key tools and see if your facility is using them properly. 5S Methodologies This is perhaps the most well known lean tool for manufacturing. It has…
Janska, a women’s clothing company that strives to keep all of its manufacturing in the U.S., recently found a way to increase sewing productivity and revenue by using a lean strategy commonly used in industrial manufacturing workplaces: one-piece flow. This method has each person on an assembly line—in this case, each sewer—perform one step of the process and then pass the item off to another person who…