Poka Yoke in the Kitchen

We have looked at common poka yoke examples in daily life. But I thought it would be a nice thing to zero down on other poka yoke examples in specific areas. These new series of posts will start with poka yoke examples in the kitchen. From the basic equipment to cooking methods, you will find that the kitchen is full …

3 Reasons Why Jidoka is not an Important Lean Tool Anymore

Jidoka Basically, Jidoka is a Japanese word that means giving machines human intelligence — this helps in building in quality into products. Stopping to fix problems is and developing countermeasures ultimately leads to better productivity in the long run. But Jidoka is not only about machines that can stop themselves. In line with the TPS philosophy, Jidoka is also about …

Kaizen Musings — Lean Inventory Management

Summary Inventory quantity is a measure of how well lean has matured Reducing inventory without streamlining processes can be a recipe for disaster Inventory velocity is more important than inventory reduction Supplier management to align to lean goals is key How inventory is received matters Inventory is Muda The ideal situation in lean is to have zero inventory. But for …

Kaizen Musings — In Lean, Slow is Better than Fast

One of the greatest selling points of lean is that it leads to faster throughput. You would expect people in a lean plant running around frantically producing goods very fast. But the reality in a truly lean organization is markedly different. While the output is very high, you will also notice that people are working at a comfortable pace. Why …

Nemawashi Model for Decision Making

Nemawashi is consensus based | Source What is Nemawashi? Nemawashi is a Japanese term which literally translated means ‘work around the roots’. It is a consensus building technique that aims at removing obstacles to proposal approval by seeking an informal audience with the decision makers before a formal meeting is held. The concept is not about lobbying as many people think of …

HOSHIN KANRI — Policy Deployment Meaning & Examples in Manufacturing

What is Hoshin Kanri? Hoshin Kanri is a management process that aims at aligning a company’s functions and activities with its strategic objectives. The process involves developing specific plans which consists of precise goals, actions, timelines, responsibilities and metrics. Hoshin Kanri usually starts with a high level organizational plan that involves setting of all the necessary goals required to achieve …

Lean Kata: Daily Improvement Practice Routine

After unsuccessfully trying to implement lean, most managers end up blaming the workers as being against lean. While resistance is to be expected in any change program, the reasons for lean implementation failure are many. But the most ignored aspect when trying to implement lean is the psychology of change within the organisation. Everybody behaves in a certain way because …

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 …