Showing posts with label Productivity. Show all posts
Showing posts with label Productivity. Show all posts

Sunday, 2 October 2016

Eliminate Waste with Lean Business Model

Article extract from ReliablePlant newsletter:
http://www.reliableplant.com/Read/29119/lean-business-model

The United States has created levels of wealth well beyond any other civilization in history, yet much further potential is sitting right under our noses. This potential lies in lean thinking; that is, the lean business model. Applying the lean business model across the board would lead to immense productivity improvements and create an environment of deflation (a deflationary economy) and very significant wealth creation. This situation would replicate the near-zero inflationary period the United States benefited from during its first 135 years.

From a historic view, inflation was and remained very small throughout the first century of our country’s existence — even up until around 1910. During this same time, income increased substantially as the country industrialized from both an agricultural and manufacturing standpoint. Much of this was driven during the Industrial Revolution, which significantly increased manufacturing output but also greatly improved agriculture output and efficiencies due to better distribution networks and the ongoing mechanization of the agricultural industry.

During this part of our country’s history, we benefited from what I call quasi-deflation; that is, though prices did not necessarily decrease, they increased at a dramatically low level over the course of many years (in fact, decades), while income that Americans earned increased substantially.

Although deflation is typically viewed in trepidation, in the past it has been— and can be in our future — a truly beneficial function. It may be viewed as price stability, enhanced buying power and value-adding.

Deflation can be defined in two ways: as a decrease in the overall price of goods and services, or as a decrease in the money supply and credit. While the second definition is considered classical economics, this discussion will use the first definition.

Applying lean is about removing waste from the system. By removing waste, work-in-process decreases, productivity increases, lead times decrease, quality improves, and on and on.

To summarize, lean reduces the cost of any product or service by eliminating waste in the development, production and distribution of these products or services. In other words, it reduces cost (notwithstanding the cultural impact and change that must go hand in hand with the cost-improvement aspect). So with all things being equal, if costs of all products and services decrease via the lean business model, that would, in turn, drive prices down over time as well.

Many products and services actually follow this model from a deflationary standpoint. For example, electronics are in a constant state of price decrease while their performance, features and quality are improving. Think of the price of iPads, HD TVs, cell phones and the like. The prices on these products can drop on a monthly or weekly basis. Obviously, improved technology is what drives price reduction in this case, combined with free-market competition. But couldn’t any product have the same pattern if lean was applied? Maybe it would not be as drastic of a price reduction or over such a short timeframe, but there is no reason why eliminating waste (costs) over time in a competitive free market could not have the same effect.

As mentioned above, our country’s history has shown that it can and has happened. Anyone who has been involved with a deep implementation of a lean business model understands the magnitude of waste that infects all business — be it manufacturing, service, government, design or distribution. For as much as we, as a nation, have yet to create, we near equally have yet to improve.

Friday, 2 September 2016

10 Keys for an Effective Lean Operation

Article extract from ReliablePlant newsletter:
http://www.reliableplant.com/Read/29017/effective-lean-operation

In my opinion and experience, there are 10 components or keys for an effective lean operation. These include:

1) Safety is not a slogan. It is acted upon and driven similar to quality and other key metrics.

2) Productivity is improving 10 percent or more per year, quality metrics are improving at 25 percent or more per year, and overall equipment effectiveness (OEE) measurements are utilized for continuous line improvements.

3) Visual controls are in place to help measure managing daily improvement (MDI). These would include things such as:

• Quality cost delivery and service (QCDS) boards are in place and acted on daily.
• Associates meet every day to review the previous day and current day.
• Statistical process control (SPC) tracking is in place on key processes.
• Andon lights and abnormality response systems are in place.

4) Housekeeping is continuously improving, making sure there is a place for everything and ensuring everything is in its place with no useless clutter. Shadow boards are being used, and lines are painted on the floor for safety and as a prerequisite for standard work.

5) Kaizen methodologies, the process of continuous process improvements, are linked to strategic objectives. Kaizen events are executed monthly to drive performance. Associates are involved and challenged. Resources are dedicated, and the company is utilizing a strong continuous improvement office.

6) Raw and in-process inventories, which are the amount of materials the plant needs for orders within five days, are moving toward a build-to-order focus. In short, you are building only what you need to fill daily orders. Create the flexibility to create any product, any day.

7) Production schedule compliance, which is meeting the production schedule as planned, is at 95 percent or greater, and the customer service index (CSI), which measures if orders are complete and on time, is at 90 percent or greater.

8) Associates are provided at least 20 hours or more per year of off-the-floor or classroom training.

9) A production process is established for daily, weekly and monthly accountability. For example, this would include:

• Daily meetings to review the schedule, quality, cost and inventory
• Weekly financial accountability meetings
• Monthly scorecard reviews
• Quarterly reviews

10) The plant is always moving toward the next record in safety, productivity, quality and inventory levels. Associates are excited about creating a positive environment where people hold themselves accountable.