Beer Game: How the Bullwhip Effect in Supply Chains Happens

                      Exploring the Bullwhip Effect using the Beer Game | Source What Is the Bullwhip Effect? The bullwhip effect in supply chains is the increase in order fluctuations as one moves upstream. It starts with a small signal in the consumption of goods by a downstream step. This small signal is misinterpreted …

5s at Home: Use this Lean Manufacturing Tool to Declutter

  Clutter overflow by Puikkibeach on flickr (cc by 2.0) | Source The amount of disorganization in your house has now become a major problem, and you are wondering what to do with all the piles of materials that are building up in every available space. You decide to do something about it but do not know where to start, and it …

14 Lean Management Principles

A lean organization achieves its goals through the application of time-tested techniques and tools, backed by a firm philosophical foundation of continuous improvement and learning. Behind the lean paradigm are a set of management principles that when consistently applied, result in business success regardless of one’s industry. What is Lean Management? Traditionally, we expect management to be the function that …

What is Heijunka?

By definition, heijunka is a production leveling and scheduling tool that is used in lean manufacturing to utilize the available capacity within an organization effectively. Responding flexibly to customer demand increases profitability. The reality necessitates production leveling and scheduling in the business world where customer demand tends to fluctuate on a day to day basis but when looked at from …

How Poka Yoke Improves Safety

Thousands of workers die or get injured on the job in the US each year. Workplace injuries and fatalities are financially and socially  [PDF] costly.  Safety features are at the forefront of most product design. No one wants to be the reason a customer was hurt or killed because of poor quality or a dangerous feature went unnoticed. Rigorous testing …

Heijunka — Production Levelling in Manufacturing

Manufacturing products is not for the faint hearted. The coordination of resources required to convert raw material to the final product can be exhausting on a normal day. To add to this, customer orders may fluctuate from day to day — leaving the plant guessing on what and how much to produce. Wouldn’t it be nice if customer orders were …

10 Ways to Improve Your Office Productivity

A hurried office can be both unproductive and unsafe. If you are too distracted and can’t focus on the content of your work, chances are you are likely to make a good number of critical mistakes. Here are a few tips and tricks you can use to increase your productivity and at the same time make your job easier and …

10 Reasons Why Organizational Change Programs Fail

Change management can sound like a scary endeavor and can cause its own crisis if not implemented properly. Sometimes change is necessary but done properly with the right tools and intentions, can enhance your business and product to be the best it can be. By steering clear of the ten mistakes below, you can give your program an excellent chance …

10 Mistakes Companies Implementing Lean Manufacturing Make

Toyota’s vaunted production system has been around for over 50 years. During that time, they have improved on their quality and productivity — in the process capturing a significant portion of the world auto market. This success has led other companies to try and implement lean manufacturing — in most cases with limited success. Why is this? The short answer …

Examples of Poka Yoke in Daily Life Situations

What is Poka Yoke? Poka Yoke is a method for drawing attention to — or preventing the occurrence of — defects. These include quality or safety defects in processes whose output is physical products and services. By addressing off-spec conditions early on in a process, costly defects in the final product are significantly reduced. Poka Yoke also refers to features …