Category: Lean

Since its introduction nearly two decades ago, Six Sigma has been embraced by many organizations and industries involved in manufacturing and transactional services as a cost-effective way to improve quality and productivity. As a method to eliminate variation and defects, Six Sigma makes use of a structured approach and statistical tools to find the root […]

A P&L manager who is preparing a monthly report starts gathering the information he needs. He realizes that this month’s sales figures are not broken out by region, so he calls accounting and asks for the regional split as quickly as possible. He also discovers that he has updates on only three of the four […]

The experience of a European life insurance provider highlights the lessons learned from transferring Lean from the shop floor to the office as well as providing a deployment model that integrates Lean, Six Sigma and process management.

Throughout my career I’ve had the pleasure of meeting colleagues from a very large variety of manufacturing cultures. Sometimes I talk to people that work in a “mass” environment with poor performance, and I hear about how good it must be to work in an efficient workplace, with relatively good performance. I always get the […]

Over the years, I’ve come in contact with several different companies that say that they are “lean”. Yes, TPS (the Toyota Production System) is a great framework for production, with its teachings of one-piece flow, kanban, etc…but what about the actual implementation of the lean concepts at other companies besides Toyota? I’ve seen desks with […]

That would be… Consultants. I was fortunate to have the opportunity to speak about lean for clinical laboratories at the recent Leadership Exchange conference, hosted by the American Society for Clinical Pathology. In discussions during the conference, I was asked many questions about the use of consultants to get started with lean. In many cases, […]

If you’d like to take a beginner’scourse on Lean, look to Ron Pereira’s Gemba Academy. He has releasedhis first video, Introduction to Lean Manufacturing. The clip below (and on the LSS Academy site) is the first 10 minutes of the 15 minute intro to Lean. Don’t waste another minute in Lean ignorance…

I was talking with a group of people about leading lean, and someone asked me, “Are you a Sensei?” So of course I said “No!” I don’t call myself a Sensei, because I consider myself to be at the grasshopper-level of lean expertise. However, the question did make me think. I call myself a Black […]

I have been thinking a lot lately about how the Toyota Production System was developed. Unlike those of us who have books, websites, and training programs in abundance, Toyota engineers took their process of assembly-line manufacture of automobiles and created, in incremental steps, the methodology that’s now known as Lean. It took shape over a […]

I’ve spent a good part of this past summer travelling for business. In the past, I might have flown a few times a year for conferences, but this year I’ve earned quite a few “miles,” Now, I know that some of you are already experienced Road Warriors, and you are probably already laughing at me, […]

When I started in continuous improvement (CI) four years ago it was via the traditional Six Sigma DMAIC route. I was indoctrinated into the Six Sigma world and have earned my ASQ CSSBB and can do impressive stuff with statistics. Lean was not even on the radar for me, it was just another approach that […]

I can’t help but wonder if banking and finance has an administrative concept equal or similar to lean process strategic planning. As accounting goes I suspect that efficiency, correct mathematical computation and balanced accounts all are considered important and of value to the banking customer. But what is the value added to high or irresponsible […]

After reading my last post, 5S Your Email Inbox, a couple of colleagues asked whether they could apply 5S to sending emails as well. Here are the guidelines that I use – I’m sure others have their methods, too, so feel free to share your own best practices! SORT 1. Ask yourself, does the recipient really […]

I love to open my business email inbox in the morning, don’t you? Especially if you’ve been practicing good work-life balance and haven’t peeked at it since the end of business the day before. When I go on vacation, it’s a special treat. Here’s a 5S strategy that I have used to keep up with […]

I have heard people say that once you have experienced the power of Lean Six Sigma that you will never be the same. I can vouch for that. Process thinking and waste elimination will begin to infiltrate every part of your life – including how you do laundry.

By popular demand, words to an old favorite tune that you can use while watching the Major League Baseball All-Star Game, at the Seventh-Inning Stretch: Take me out to the Gemba Take me out to the flow! Find me a Value Stream I can track I don’t want wasteto evercome back! For it’s root, root, […]

For defining the ’VOC’ (Voice of the Customer), I typically use a QFD (Quality Factor Diagram) — Of recent, I have found that QFD’s can be hard to understand for some, while even more painful for belts to explain to others. If you find this to be the case, there are 3 tools used sequentially […]

There’s a great quote from Shakespeare’s “Twelfth Night” that I was thinking of today, in relation to how we teach lean. Thecharacter Malvoliosays, “Be not afraid of greatness. Someare born great, someachieve greatness, and some have greatness thrust upon ’em.” So, with apologies to Will… “Some are born lean, some achieve lean, and some have […]

I was privileged to speak at a conference in San Francisco last weekend, sponsored by the American Society for Clinical Pathology. The topics focused on leadership in the clinical (medical) laboratory. After giving a presentation on 6S, I served asa panel member for questions submitted from the audience. One of the questions asked, “What can […]

In healthcare, we are definitely trying to speed things up for our patients. Billboards around our area (and maybe, around the country) promise 30 minute door-to-doc time in their Emergency Departments (EDs). One promises no waiting to be seen by a healthcare professional! Mini-offices are springing up in chain pharmacies, promising no waiting for minor […]

LSS Academy’s Ron Pereira goes live with his first vlog (video blog). In this video Ron walks us through a “one piece flow” versus “mass production” simulation to showdifferences between the two approaches. Today with his first vlog, Ron also relaunched Lean Six Sigma Academy with the added functionality of a web 2.0 site. Take a minute […]

5S is one of the foundation concepts of lean. The Japanese originals were: Seiri, Seiton, Seiso, Seiketsu, Shetsuke. (Additional S’s such asSafety or Security are sometimes added.) I did a quick survey on-line to see what variations are out there. Sort – Straighten – Scrub – Standardize – Sustain Separate – Sort – Shine – […]

A common way to learn principles or tools is to associate a word as an acronym. The seven/eight wastes of Lean is a great example of acronymic variation. I’ve come across five different words invented to illustrate the wastes of Lean: The iSixSigma dictionary uses the word DOTWIMP to list the seven wastes of Lean […]

Now we have the tools. Supervisors are watching the process, identifying muda, re-work and redundant processes. Front line staff are meeting production goals within acceptable standards. Our work-in-progress is flowing with less wait time, a focus on pull of resources and just-in-time customer service. We are sustaining production within dictated standards. What is next? A […]