How to Sustain a Lean Culture in Manufacturing & Supply Chain

Cerasis

Today I will discuss how a company can sustain a lean culture once they have implemented lean practices in order to achieve continuous improvement. Your company has started the lean journey, but how do you sustain it? Lean Culture by Creating "Standard Work".

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Lean Manufacturing

LeanCor

A motor manufacturer’s warehouse space and on-hand materials were growing exponentially as it received, processed, and stored material for potential future use. Additionally, right sizing of the inventory strategy allowed for anticipated production growth.

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When is Inventory Too “Lean”? Finding the Right Balance

ToolsGroup

I learned about “lean manufacturing” (or simply “lean”) back in the 1990s when I met James Womack and read his book “ The Machine that Changed the World ”. But we have also seen companies misinterpret the lean message when it comes to inventory.

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Lean Manufacturing: Is it Really Worth It? 16 Big Benefits Say, “Yes.”

Cerasis

Customer expectations of reliable quality and rapid delivery forces today’s manufacturers to either shorten cycle times or lose business. Lean systems have provided a formidable operating strategy for leaders determined to achieve and maintain optimal operational systems and customer satisfaction levels. There are multiple good models for lean manufacturing operations. Who Needs Lean Manufacturing? Holding areas are maintained for excess inventory.

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Lean Manufacturing

LeanCor

A Systems Approach to Inventory Management. Inventory Management. Lean principles focus on eliminating waste from business processes. Inventory is not isolated to raw materials and finished goods. Companies will carry inventory masquerading as service parts, repair items, administrative suppliers, automobile fleets, and a host of other types of assets that are managed by setting and maintaining certain levels. Inventory Management Processes.

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Understanding Lean and the 8 Wastes

The Logistics of Logistics

Understanding lean and the 8 wastes is important for all operations people including logistics and supply chain folks. The concept of lean (and the 8 wastes) originated in the manufacturing sector where it was first recognized that eliminating waste in the system led to much bigger profits. Henry Ford and his team at Ford Motor Company discovered lean along with the assembly line, even though they didn’t necessarily use the term lean. Excess Inventory.

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9 Steps to Establish the Lean Supply Chain: A System of Interconnected & Interdependent Partners

Cerasis

Top management knows that lean can add value , but many still haven’t moved past the initial education stage into full-scale lean supply chain implementation. One reason may be that they haven’t made the paradigm shift as to how to implement lean. Consider Lean Accounting.

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Applying Lean 6 Sigma Principles to the Supply Chain

Logility

Fifteen years ago, I worked for a company that embraced Lean 6 Sigma as a core operating fundamental. Just about every member of the management team was a Lean 6 Sigma Black Belt and many had attained a level of Master Black Belt.

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Lean Transportation: Are you Using Lean Thinking for Transportation Management? If not, Why?

Cerasis

Lean is a new way of doing business. For shippers, culture and behavior have to change to apply Lean Transportation thinking. Lean thinking focuses on the elimination of all waste (where waste is defined as any non-value added process) and bringing value to the customer , beyond the customer’s expectations. The “Them (company leadership) versus Us (shop floor associates)” mentality also needs to change for Lean Transportation to " WE.

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Lean Warehousing

LeanCor

Lean Warehousing – From Paradox to Operational Excellence. Before we start talking about Lean Warehousing, can you tell us a little bit about LeanCor Supply Chain Group? We want to help our customers succeed in their quest for lean and operational excellence.

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Warehouse Cost Reductions: 3 Understandings Driven By Inventory Management & Lean Principles

Cerasis

Today, I will now address how a focus on inventory will allow for warehouse cost reductions as well. A Focus on Inventory Control Begets Warehouse Cost Reductions. First, look at inventory as MONEY/CASH. Inventory cost is defined as the cost of holding goods in stock.

Lean Culture

LeanCor

Building a Lean Culture: A Food and Beverage Case Study. LeanCor has partnered with food and beverage manufacturers, distributors and resellers of an assortment of products ranging from bottled water and frozen dinners, packaged snack foods and candies, to refrigerated deli sandwiches.

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Leaning Towards S&OP/ IBP

Logility

Many companies have high hopes when they set out to implement a Lean improvement program. A growing body of knowledge and experience indicates that Integrated Business Planning (IBP) may be the key ingredient for lean success.

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Lean Manufacturing Driven by Rapid Return on eKanban Technology Investment

synchrono

Lean Manufacturing relies heavily on trusted relationships with suppliers and pre-negotiated terms of engagement. An eKanban Pull-based inventory replenishment system monitors that each aspect of the service level agreement is being met by the supplier in real-time.

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Inventory Management in Manufacturing Environment

LeanCor

Firms today are beginning to understand more and more that high levels of inventory aren’t just detrimental to costs but also for hiding other potential issues. The beginning stage of inventory management doesn’t begin at the dock door rather it begins with the supplier.

Lean Manufacturing Systems: How Mobility Empowers the New “Lean”

Cerasis

The use of lean manufacturing systems has become commonplace in modern manufacturing. Lean manufacturing refers to eliminating waste, reducing costs, and improving production with finite resources. This information is then available to the manufacturer's employees.

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Lean Six Sigma

LeanCor

What is Lean Six Sigma Logistics? Lean Six Sigma is the combination of two methodologies that complement one another when applied to logistics and supply chain management. Lean Six Sigma Logistics: Lean and the Logistician.

Lean versus EOQ? What’s best for your organization?

Kinaxis

In no time at all we were debating between lean versus EOQ. It doesn’t matter if you’re a technician working on the shop floor or an executive in the board room, if you’re in the business of manufacturing then this is a conversation you’ve had before. You’ve ‘gone lean’ but aren’t!

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Metrics that Matter: Inventory Effectiveness

QAD

The effective use of a manufacturer’s inventory investment is an important determinant of the company’s success. Excess and obsolete inventory is a drain on resources, as is excessive safety stock. Managing an Inventory Investment.

Introducing Lean In Retail … Start in the Backroom!

Supply Chain Game Changer

Check out 10 Signs You Should Reboot Your Lean Program! I decided that I would introduce Lean process improvement techniques to this company. I came from a Manufacturing, Operations and Supply Chain background so I spent a career surrounded by the application of Lean methodologies.

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Applying Lean Principles to Supply Chain Planning

Logility

Today, Lean is a concept, a philosophy, a practice, and a set of tools all wrapped in one. The focus of Lean is to maximize quality, minimize unnecessary steps and optimize customer value (provide them what they want when they want it).

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Multi-echelon Inventory Optimization and Lean/Six Sigma

Supply Chain Action Blog

How Lean Thinking Helps. Lean principles are applied to drive out waste. One of the most predominant lean tools used for identifying waste is Value Stream Mapping which helps identify eight wastes, including overproduction, waiting, over-processing, unnecessary inventory, handling and transportation, defects, and underutilized talent. In inventory management, this often happens through a reduction of lead times and lot sizes.

FAQ: Is Demand-Driven Manufacturing the Same Thing as Lean?

synchrono

Many of our customers don’t start out looking to implement Demand-Driven Manufacturing per se. Often, they’re focused on Lean Manufacturing or at least some element of it. Another term commonly used for Demand-Driven Manufacturing is pull-based or demand-pull manufacturing.

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Multi-echelon Inventory Optimization and Lean/Six Sigma

Supply Chain Action Blog

How Lean Thinking Helps. Lean principles are applied to drive out waste through a reduction of lead times, lot sizes, and activity that does not increase the value of the whole. Lean principles have been encapsulated by the five S’s, taken from the transliteration of five Japanese words, which, in turn, have been translated into English counterparts. Seiri (Sort) – sorting, i.e., proper arrangement of all items, storage, equipment, tools, inventory and traffic.

Seven Misconceptions on Managing Inventory in a Market-Driven World

Supply Chain Shaman

When it comes to the management of inventory in value chains, frustration abounds. Executive, after executive, lament, “They have purchased many technologies and sponsored many projects to reduce inventories, but they are not seeing results.”

The Agile Supply Chain! Why Agility is Trumping Lean!

Supply Chain Game Changer

Check out 10 Signs You Should Reboot Your Lean Program! Once, the lean supply chain was considered to be the most effective form of manufacturing and supply chain management. Unfortunately, many supply chain entities do not understand or fail to grasp the full scope and concept of agility and how and it functions in relation and contrast to a lean supply chain. Let’s take a look at how the agile supply chain is quickly replacing the lean supply chain.

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Uncork Manufacturing Bottlenecks for Optimized Production

USC Consulting Group

In the manufacturing sector, however, bottlenecks can be a serious drain on productivity, revenue, efficiency, and asset utilization. What does a bottleneck mean in manufacturing terms? However, in manufacturing, bottlenecks have their own clear-cut definition as well.

Reshoring Or Not, What is Manufacturing? 4 Questions to Ponder with Real American Manufacturers

Cerasis

We recommend you get in touch with him if you'd like an expert to guide you to the next level in your manufacturing business. . Reshoring Or Not, Let's Get Back to the Basics of What is Manufacturing. What is Manufacturing? These manufacturers are called Subcontractors.

Agile Supply Chain: Why Agility is Trumping Lean in the Supply Chain

Cerasis

Once, the lean supply chain was considered to be the most effective form of manufacturing and supply chain management. Let's take a look at how the agile supply chain is quickly replacing the lean supply chain. How Is Agility Fundamentally Different From Lean Concepts?

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Common Sales and Operations Planning Myths Part 5 – Lean and On-Demand Manufacturing

Logility

Today we are going to look at lean manufacturing. Myth: “No Need for S&OP; We have Lean Manufacturing.” ” Some proponents of lean manufacturing believe that if you are running lean processes where you have eliminated waste, raw and work in process (WIP) inventory will be delivered and used just-in-time (JIT) to meet customer demand. Raw and WIP inventory takes time to procure, build and transport.

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3 Tools to Minimize Waste: A Boon to Lean Manufacturing Strategies

Cerasis

Lean manufacturing is one of the leading waste minimization technologies inside a manufacturing industry. Most of the manufacturing industries have already incorporated lean manufacturing strategies to undermine the non-additive materials from their products. Companies of all sizes are incorporating the lean principles and realizing a dramatic improvement in quality, productivity and most importantly customer experience. Lean Manufacturing

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Trends In Manufacturing: 5 Tangible Technologies are Shaping the Future of Manufacturing Now

Cerasis

Continuous improvement is part of the game in manufacturing. Among the new trends in manufacturing improving the industry, additive manufacturing and cloud-based systems will push manufacturing forward in 2017. In fact, rapid design and lightning-fast prototyping, reports Mark Dohnalek of Manufacturing Business Technology magazine , will allow manufacturers to design and produce products in a few days, if not hours. Manufacturing

Manufacturers Should Focus on This Most Critical Component for Manufacturing Operations Excellence

Cerasis

We conclude this two part series about manufacturing operations excellence by consultant Chuck Intrieri, by outlaying why manufacturers should focus on a critical component that will help sustain manufacturing operations excellence for years to come. What is Driving Sustainable Manufacturing Operations Excellence? What is the most important part of manufacturing? The most important resource in manufacturing is people.

4 Key Trends to Watch in Smart Manufacturing and Supply Chain

Cerasis

The advancements in 3D printing and 'Additive Manufacturing,' coupled with supply chain efficiencies, could make distributed manufacturing a reality, ushering in the era of smart manufacturing. The Continual Coverage and Now Reality of Smart Manufacturing with 3D Printing.

6 Recent Trends in Manufacturing Technology to Increase Agile Responsiveness, Continuous Improvement & Customization

Cerasis

A Quick Recap of Recent Trends in Manufacturing Technology to Think About 2017. Although apps and smart devices will make an impact in manufacturing technologies this year, a few other recent trends in manufacturing technology will dramatically redefine industry standards.

6 Manufacturing Trends to Watch Out for in 2016

Cerasis

As we close the year of 2015, we want to take a look at some manufacturing trends for 2016. We look at 6 core areas that manufacturing companies will take a long look at as they gear up for a successful 2016. E-Commerce for Manufacturing. Manufacturing manufacturing trends

Manufacturing in the Age of Uncertainty

QAD

But what if every pizza shop in America all of a sudden asked a single pizza oven manufacturer to build and ship an extra oven per shop? How does a manufacturer organize operations to meet unexpected demand shifts without creating inefficiency for the rest of the year?