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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? Let's first talk about first setting the stage, then give you practical practices and tactics to achieve a sustainable lean culture, and then provide core key performance indicators (KPIs) to track your progress. 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. As a result, warehoused inventory increased from one to seven warehouses due to lack of a defined inventory and replenishment strategy. LeanCor used PFEP as the foundation of the future state parts strategy and 5S to sustain optimal inventory levels and locations.

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Supply Chain Leaders Rearranging Deck Chairs? Yes, I Think So.

Supply Chain Shaman

After finishing the Supply Chains to Admire report and the Youtube series (to be released this week), this is my feeling. What Is Supply Chain Excellence? In the review of my first book, Bricks Matter , Keith Harrison, former Global Director of Product Supply at P&G asked me, “You mention the need for supply chains to shift from a focus on cost to value. My first observation is that the best supply chains are fit for function.

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. The Lean Supply Chain is a system of interconnected and interdependent partners that operate in unison to accomplish supply chain objectives. This sets the supply chain pace.

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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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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 ”. Based on MIT's five-year, fourteen-country study – one of the largest and most thorough ever undertaken -- the book describes the entire managerial system of lean production. In the last twenty plus years “lean thinking” has fundamentally changed the way many companies, and sometimes whole industries, operate.

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Supply Chain 2030: Forge a New Path

Supply Chain Shaman

The Supply Chain Insights Global Summit is over, but we hope the energy to define Supply Chain 2030 is just beginning. Today only 12% of supply chain teams are driving improvement, performing better than their competitors and driving value (as determined by Price to Tangible Book Value). As companies prepare for Supply Chain 2030, we think that it is time to rethink the basics. Seven Predictions for Supply Chain 2030.

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.

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Marketing Supply Chain Solutions Post-COVID: Q&A with ToolsGroup CMO Caroline Proctor

ToolsGroup

There’s still a strong demand for supply chain planning solutions, particularly ones with machine learning capabilities that can help clients rapidly adapt to the changing supplier situations and consumer demand that goes along with major disruptions like this. .

Lean Warehousing

LeanCor

Lean Warehousing – From Paradox to Operational Excellence. A conversation and exclusive interview with Tonya Vinas, B2B writer and editor, and Robert Martichenko, CEO, LeanCor Supply Chain Group. Before we start talking about Lean Warehousing, can you tell us a little bit about LeanCor Supply Chain Group? Sure, LeanCor is a trusted supply chain partner that delivers operational improvement and measurable financial results.

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4 Supply Chain Areas to Examine in the Face of Disruption

QAD

Global supply chain leaders have broad and continuous experience in expecting the unexpected. How do Disruptive Events Impact the Supply Chain? The supply chain impact resulting from coronavirus varies heavily depending on the industry. These are just a few examples of how a crisis may increase or decrease demand for particular products resulting in supply chains being impacted. . Boost Global Supply Chain Visibility.

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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. For more than 50 years, organizations have invested time and money adopting the principles of Lean (while originated at Toyota Corporation for manufacturing operations, the principles of Lean have since spread to many types of businesses and functional areas). The two primary principles of Lean, Just in Time and Jidoka, are referred to as the pillars of the lean philosophy.

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Supply Chain Shifts From Lean Model

AB&R

The last few months have put the supply chain to the test. With the supply chain’s lean model, many retailers were not able to respond to the sudden changes in demand. The study also predicts more demand as a result of shifting manufacturing locations to on-shore or near-shore. The post Supply Chain Shifts From Lean Model appeared first on AB&R. We’ve seen strong points and weaker areas.

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Lean Supply Chain: The Culture That Must Be Fully Embraced

LeanCor

By: David Sherman – Lean Logistics Specialist. By maintaining lean practices and instilling lean cultures into their employees and work environment firms are able to realize this success. These lean practices and cultures lead to firms transforming their habits based on customer demand rather than by supplier constraints. What is the lean supply chain? How does the lean supply chain function?

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Lean Thinking Revisited

Operations and Supply Chain Management

The supply chains for consumer goods in the U.S. The sputtering supply chains are putting a new spotlight on the just-in-time strategy born in the hyperefficient Japanese automotive industry that became a religion for many American executives.

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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 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. These are companies that embrace lean and recognize that the organization is only as good as its people. Lean Culture Current State: Customer Challenges in the Food and Beverage Industry.

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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.” ” I have been studying the evolution of inventory technologies as an industry analyst since 2002. The supply chain is a complex system with increasing complexity. The Inventory Management Journey.

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. EOQ attempts to optimize lot size by balancing manufacturing cost ( Fixed + variable costs) with things like inventory holding costs and capacity utilization. You’ve ‘gone lean’ but aren’t!

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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. Through the use of supplier quality certifications and blanket (long-term) purchase orders, a manufacturer can accurately and effectively calculate the optimal level of inventory needed to fulfill demand requirements through the duration of replenishment lead time. Eliminating inventory waste. Pull Manufacturing with Kanban.

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The State of Supply Chain Trends Part II: AI, Procurement, & the New Lean

Cerasis

Understanding how different factors affect the supply chain remains a top priority for research firms around the globe. From artificial intelligence to refocusing on procurement, the state of supply chain continued to explode throughout 2016, and you need to understand why. The State of Supply Chain 2016 Trends. Additionally, the push toward creating a self-sufficient AI is growing stronger among supply chain professionals. Supply Chain

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Vendor Managed Inventory Model for Supply Chain Cost Reductions

Cerasis

As a supply chain director, manager, or boss of a multinational corporation, where the supply chain is an integral part of your business, supply chain cost reductions are always at the forefront of your team’s mind. You can employ countless number of supply chain service providers who will help realized these cost reductions throughout the entire supply chain. The distributor maintains the inventory plan.

4 Key Trends to Watch in Smart Manufacturing and Supply Chain

Cerasis

Industrial IoT and big data are converging to enable demand-driven 'smart supply chains.' 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. Smart Manufacturing will Make Supply Chains Demand Driven not Forecast Driven.

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. The impact of Lean on the logistician is significant. A common misconception of Lean philosophy is that it only finds application in manufacturing settings. Lean Six Sigma Logistics: Six Sigma and the Logistician.

Lean Principles and Sales & Operations Planning (S&OP)

Logility

Many companies have high hopes when they set out to establish a Lean operating environment. A growing body of knowledge and experience indicates that advanced Sales & Operations Planning (S&OP) may be the key ingredient for Lean success. Lean applied to supply chain operations is all about creating capabilities that efficiently move materials from raw through finished product, and then to the customer.

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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. Inventory management starts with lean buying and planning tactics as well as streamlined inventory management standard processes for material handling and planning. The beginning stage of inventory management doesn’t begin at the dock door rather it begins with the supplier. By: David Sherman.

Top 10 2020 Manufacturing Trends

IQMS

Bottom Line: 2020 manufacturing trends are driven by manufacturers’ strong confidence in their ability to deliver high-quality products that earn repeat orders while delivering excellent customer experiences. Running Lean While Focusing On Keeping Margins Strong.

Carter’s: A Story of Supply Chain Leadership

Supply Chain Shaman

To drive global scale, companies need to design the supply chain to buy globally and execute locally. The design of the supply chain is fundamental to making this happen. In our interview of the Supply Chains to Admire Winners, we found a unique approach at Carter’s. Shipping approximately 400 million selling units consisting of 700 million manufactured units per year, Carter’s employs about 4,000 employees at its peak. Supply Chain Index.

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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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. If you are looking for warehouse cost reductions, chances are you are stocking too much inventory. Understand Data Integrity to Reduce Inventory Costs. Lean is a new way of doing business.

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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. Lean is all about creating a physical environment that enables material to flow efficiently from raw through finished product to the customer. The perfect enabler for Lean success is called Integrated Business Planning.

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Balancing service levels and supply chain costs

ToolsGroup

Precisely balancing the tradeoff for each inventory item is a hallmark of inventory optimization. Editor’s Note: Last year ToolsGroup became Microsoft’s partner for Multi-echelon Inventory Optimization (MEIO) in Industrial accounts. Multi-Echelon Inventory Optimization.

Supply Chain KPIs You’ll Want Every Morning

Logility

A quick scan of the Internet will yield a long list of “the biggest-ever supply chain disasters”. in inventory write-down and 20% drop in stock value. Would access to better supply chain and IT performance information have helped avert or mitigate these failures?

Manufacturing ERP Plays a Key Role for Sustainability

QAD

While consumer products manufacturers previously led the way for sustainable manufacturing practices, a growing number of manufacturers in other sectors are treating sustainability as an important operational objective to increase global competitiveness. The Sustainability Movement in Business and Manufacturing. Many manufacturers now publish separate sustainability reports or incorporate the information in their annual report including Nexteer, Tesla, Ball Corp.,