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Why Lean Business Processes Fail – Does your “Gate” Have No “Fence”?

Published: June 1, 2015
We have all read the books, we all know the theory – Lean business processes are GREAT! They cut waste, cut lead times and streamline processes. However the little secret that no one will tell you is that sometimes they just don’t work! In this blog we discuss a key reason why this happens. ... Read more

Seven Reasons NOT to Fire your Factory Manager

Published: May 20, 2015
The role of Factory Manager (or Operations Manager, Plant Manager, General Manager – title is not important) is one of the most challenging in business. In most cases firing the Factory Manager is does not improve manufacturing performance and often makes it worse. So before you “push the button” on firing your Factory Manager, read our “Seven Reasons NOT to Fire your Factory Manager”: ... Read more

The Metrics of Concern Strips

Published: March 29, 2015
Across manufacturing sectors we are living in a data-rich world, which is both a blessing and a curse. Data can take many forms and often changes as the needs of business change. At one end of the spectrum we have hand-drawn, manually collected metric charts. These progress all the way to advanced MRP systems that can turn reports in visualisation resources to make graphs of anything you want, but too much data quickly becomes noisy and un-actionable, so which metrics do you need to focus on? This article will focus on the metrics and systems we create around Solving Problems Every Day (SPED) and Concern Strips as the key element of SPED, including Time to Resolution, Time to Respond and Escalations. ... Read more

Creating a Standard Lean Workstation in a Low Volume, High Mix Industry

Published: March 24, 2015
When a team of craftsmen come together to discuss their needs for a standard lean workstation, you can imagine the struggle this can be for a team who is just starting on their Lean journey. Our craftsman work in a low volume, high mix industry. Designing a standard Lean workstation is the first steps towards developing work standards. Here are the three key steps in creating a standard lean workstation. ... Read more