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: 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? Lean Manufacturing Planning and Implementation.

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Lean Manufacturing

LeanCor

Lean principles focus on eliminating waste from business processes. Whenever decisions are made in purchasing, marketing, manufacturing, o r customer service, inventory levels across these asset types will be impacted. For example, it is extremely hard for an inventory analyst to attempt to reduce inventories when the manufacturing area is frequently changing production schedules without informing the inventory analyst of the changes. Lean is about the elimination of waste.

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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.

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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? As a third-party logistics provider, LeanCor offers a unique combination of third-party logistics services, hands-on consulting, and training and education that helps organizations eliminate waste, drive down costs, and instill a problem-solving culture across their supply chains.

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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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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. Flow in the lean supply chain begins with customer usage.

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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. As Director of Logistics and Planning, part of my responsibilities were to manage our relationships with outsourced manufacturing partners including quality. Small children are especially good at this lean tool because they love to ask “why?

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Lean Six Sigma Training

LeanCor

Lean Six Sigma Training focuses on the improvement of the quality of numerous process outputs. It also helps minimize variability in business processes and manufacturing. Lean Six Sigma Training also helps instill a very lean problem solving culture. At the same time, its curriculum emphasizes lean supply chain, problem solving and lean leadership. Lean Six Stigma Training utilizes a hands-on approach. A Unique Training Regimen.

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. However when I started the discussion around deploying Lean at this Retailer virtually everyone had no knowledge of what Lean was. Our Lean journey had begun.

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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? So, what stage of lean is your firm currently in?

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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.,

How to Become a Lean, Green Manufacturing Machine

Cerasis

Lean and green are not only trendy topics, but they also make good business sense, especially for manufacturers. However, since both concepts have been saddled with a lot of hype, manufacturers have tended to shy away from pursuing these goals. Get Lean the Easy Way. In reality, one of the core tenets of the Toyota Production System on which lean manufacturing is based is “produce only what you need to satisfy the customer and nothing more.”.

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

Cerasis

This is the second part of my series on various ways to reduce overall costs as it relates to logistics and warehouse cost reductions. In the first part I put forth 6 areas of focus in order to reduce logistics costs. In order to avoid excess inventory and keep your business lean, you must understand the pace of movement of each product. Understand Lean Principles and How to Use them to Cut Out "Waste". Top Management must commit and focus on Lean.

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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.

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

How to Become a Lean, Green Manufacturing Machine

Cerasis

Lean and green are not only trendy topics, but they also make good business sense, especially for manufacturers. However, since both concepts have been saddled with a lot of hype, manufacturers have tended to shy away from pursuing these goals. Get Lean the Easy Way. In reality, one of the core tenets of the Toyota Production System on which lean manufacturing is based is “produce only what you need to satisfy the customer and nothing more.”.

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How Lean Warehousing Can Ease Your Carrier Capacity Pain

LeanCor

Lean Warehousing: By: Clint McCrystal – Team Leader of Operations. Ask anyone in transportation management/logistics/supply chain and they will affirm this statement. One specific type of lean warehousing that one of our customers has available to them comes in the form of a cross-dock. This cross-dock allows our logistical engineering team to help their supply chain control flow, improve delivery timing, reduce transportation and increase stability.

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The Growing Reliance on Traceability in Manufacturing Supply Chains

IQMS

Bottom Line: The heightened priority on health & safety is leading to a renaissance of traceability in manufacturing across many industry sectors as every business strives to keep its employees, customers, and suppliers safe. Reliance on Traceability in Manufacturing Is Growing.

4 Best Ways Manufacturers Can Perfect Their Supply Chain

USC Consulting Group

Leading the way — and defying the odds — are manufacturers. Yet with COVID-19 and product shortages still a reality, some manufacturers are wondering what they can do to improve their supply chain resiliency to prepare for present and future disruption. In a separate poll conducted by the ISM, purchasing managers at some of the largest manufacturing companies expressed ongoing unease about future shocks to their supply chain while they scramble to remedy current shortages.

Lean Defined: What is Waste? (In Logistics)

LeanCor

Lean Defined: What is Waste? (In In Logistics). The first step in lean thinking is to understand what is value and what activities and resources are necessary to create that value (“value-add”). ” Lean practitioners use the Japanese term “ muda ” when referring to waste, although they have typically done so in a manufacturing context. This trade-off describes our challenge to manage total logistics cost. Image via Wikipedia.

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Supply Chain Shifts From Lean Model

AB&R

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. Costco’s recent acquisition of logistics company, Innovel, echoes these findings. The post Supply Chain Shifts From Lean Model appeared first on AB&R. The last few months have put the supply chain to the test.

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

Cerasis

Consequently, all processes, including inventory management, logistics, data analytics and ongoing performance management, as reiterated by the staff of Supply Chain 24/7, improvement, can be optimized, creating a more efficient, direct and intelligent supply chain network. Agile = The New Lean. Another key player in the 2016 state of supply chain report was the move away from rigid, lean processes to agile methodologies.

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

Cerasis

Editor's Note: This is a two part series featuring Chuck Intrieri, who along with providing excellent insights over at his industry leading The Lean Supply Chain blog, is also a consultant who works with companies for Cost Reduction, Supply Chain Optimization, Logistics, Manufacturing, and 3PL Selection. 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. . What is Manufacturing?

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. I remember reading an MIT paper on manufacturing technology trends a couple of years ago. It had a fascinating mention of " Additive Manufacturing " (AM) and how it could be a game changer.

Lean on a 3PL to avoid warehouse staffing challenges

Kanban Logistics

For many shippers and manufacturers, warehouse staffing has long been a major supply chain challenge. In this article, we’ll examine 4 labor-related benefits that come with entrusting your warehousing operations to a third-party logistics provider (3PL). When in-house resources won’t meet volume demands, 3PLs can lean on their temporary-labor-agency partners to fill in the gaps. Lean on Kanban Logistics and leave your warehouse staffing challenges behind.

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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. The Internet’s large-scale global penetration has spawned an increasingly large number of technology and web-savvy consumers, creating a huge opportunity for both industrial manufacturers and their end customers.

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The Top 5 Manufacturing Blogs of 2016 …So Far

Cerasis

We continue our series on the top 5 blogs in our 4 main categories ( Freight , Manufacturing , Logistics , and Supply Chain ). Our last post covered the Top 5 Logistics blogs of 2016. Today's post will cover the top 5 manufacturing blogs from 2016 so far. Top Manufacturing Blogs from the First Half of 2016 So Far. The manufacturing blogs category most top viewed blog posts from the first half of 2016 included several elements of manufacturing.

Why Lean Fails in Manufacturing, Distribution or Service Industries

The Lean Supply Chain

I interviewed Chuck Intrieri who discussed Why Lean Fails in Manufacturing, Distribution or Service Industries. Lean is not a project. Lean is not a set of tools. Lean is a philosophy. Lean is the elimination of all waste and bringing value to the customer. Lean is a paradigm shift. Training is continuous as the Lean implementation continues. Lean will fail if top management does not get behind it. They should be part of Lean teams.

50 Most Read Articles of All Time in Manufacturing, Supply Chain, Logistics, Transportation, & Freight

Cerasis

Since today is the last day of the year before we all get ramped up towards a productive 2016 and after finishing out top 10 most read articles in each of our five main categories ( Manufacturing , Supply Chain , Logistics , Transportation , & Freight ) we wanted to give you all a treat and list the top 50 most read articles of all time from the Cerasis blog. Lean Initiatives: Understanding at a High Level & The Benefits of 5S. Layers of Logistics Explained.

Sustainable Logistics: Quantifying Sustainability Measures of Your Logistics

Cerasis

Calculating the carbon footprint of a company’s comprehensive logistics framework is tremendously complex. Creating more sustainable logistics is even more important for the trucking industry. Sustainable Logistics | Quantifying Sustainability Measures of Your Logistics. Robinson and the MIT Center for Transportation and Logistics. From shareholders to consumers, sustainable logistics has created broad value. Logistics

Analytics in Distribution and Manufacturing Taking Center Stage

Cerasis

Part of this drive toward more interest in analytics in distribution and manufacturing comes from the ability of analytics to reduce inefficiencies dramatically and increase productivity in both physical and virtual sales environments. Furthermore, analytics are becoming more widely available through the cloud, and manufacturers and distributors of any size can reap significant benefits from implementing analytics in their operation, explains Eric Smith of Modern Distribution Management.

Keeping Sustainability at the Forefront of Packaging Manufacturing

QAD

No manufacturer would be blamed if they put operational sustainability plans on the back burner during the current environment. Yet it seems sustainability will surely survive this moment, which means manufacturers must stay vigilant. .

Inventory Management in Manufacturing Environment

LeanCor

Inventory management starts with lean buying and planning tactics as well as streamlined inventory management standard processes for material handling and planning. Firms need to advise their suppliers of their consumption (customer demand) so that they can match buying and manufacturing processes for both parties. Once the collaboration has begun with supplier(s), internal processes can be geared toward lean receiving and warehousing functions. By: David Sherman.

LEAN throughtout the Supply Chain

The Lean Supply Chain

Supply Chain management is one of the main disciplines of any economic sector from manufacturing to distribution to retail. A Third Party Logistics (3PL) provider and the Supply Chain: 3PL warehouses, fulfills, and distributes wine to the ultimate customer, sometimes called “white glove, last mile.”. A Fourth Party Logistics (4PL) provider and the Supply Chain; manages the entire supply chain from the Supplier to the ultimate customer. Why extended Lean in the Supply Chain?

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