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Jan 13 2012

Lean = outsource, fire people, and apply ERP ???

Via Scoop.it – lean manufacturing
This is an unusual take on Lean from a UK ezine. We should recommend homework to the author.

“Following the recession, many businesses have adopted lean principles in the most obvious areas, such as moving production to cheaper locations or reducing non-essential staff. However, simple cost cutting is only a part of the story. To be truly lean, a business also needs to reduce inefficiency in less obvious areas. By using Enterprise Resource Planning (ERP) software, companies have a complete, integrated overview of their entire organisation, combining information from all business areas into one simple system.”

Via www.businesszone.co.uk

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By Michel Baudin • Press clippings • 0 • Tags: Lean, Lean manufacturing, Management

Jan 13 2012

5S First?

Via Scoop.it – lean manufacturing

I agree with the comments, but not with the heckler’s assumption that 5S is easy. It may look easy, but, if it really were, 5S efforts would be successful more often. The key reason it should almost never be done first is that it is so hard to make it stick. Companies that start with 5S usually have a big spring cleaning event followed by rapid backsliding that destroys the credibility of 5S with their work force.
A consultant who recommends 5S first is like a parent telling a kid to clean up his room because he has problems at school. It probably needs doing, but it won’t solve the school problems.

“Some time ago, while speaking at a conference in the land down under, I was taken to task by a participant for suggesting, “5S is usually the first improvement” in Lean implementation.”
Via oldleandude.com

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By Michel Baudin • Blog clippings • 3 • Tags: 5S, Lean implementation, Management

Jan 12 2012

Steve Jobs as a Model Leader? As a Manufacturing Leader?

Via Scoop.it – lean manufacturing

Blog post at Lean Blog : As I wrote about after his death, I am appreciative of the products and services that Steve Jobs brought to the world.  That said, some of [..] (From our free app: Steve Jobs as a Model Leader?
Via www.leanblog.org

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By Michel Baudin • Blog clippings • 0 • Tags: Management

Lean certificate

Jan 11 2012

Certification, shmertification!

Several of the comments on Six Sigma R.I.P.   touched on certification. With the belt system, this issue is of course central to Six Sigma, and, with Six Sigma on the Lean bandwagon, is merging with that of Lean certification, as evidenced in plant Lean champions who introduce themselves as Black Belts.

In his comment, R. Kester said the following:

Certification is the accepted way to communicate to others that you have successfully studied and can apply the concepts and tools of your profession (CPA, MD, RN, PE, etc.).

It is true that you want a Certified Public Accountant to help with your taxes, and that, if you go to a clinic, you don’t want anyone to mess with your health who doesn’t have the proper credentials posted on the wall. On the other hand, if you buy a painting, you usually don’t care whether the artist learned the craft in a school of fine arts or by spraying city walls: the paintings tell you all you need to know. There are also fields where certification exists but is not necessarily sought by all. For example, many university engineering departments seek ABET (Accreditation Board for Engineering and Technology) certification, but some don’t, such as Electrical Engineering at MIT, UC Berkeley, or Stanford. Their own brands are more prestigious and better known than ABET.

In the continuum of certifiable human activities, where does Lean sit between MDs and CPAs on one side and artists on the other? Lean experts sell their services to businesses, not consumers, and the primary use of certification is as a job applicant filter. To a recruiter with no personal knowledge of Lean and 100 resumes to review, the absence of a Lean certification is quick way to dispose of 80%. But what guarantee does the Lean certification give  that the surviving 20% are the best candidates?

For a certification process to achieve this result, there has to be a consensus on a body of knowledge (BOK) and on institutions qualified to certify proficiency in its application. Having doubled life expectancy in 200 years, modern medicine is a credible BOK. We know its theories are sound because they prevent, cure or control many diseases. Tax law is different, in that it is a set of rules defined by people for people to follow, like the rules of poker.  Outside of a specific human society, there is no corresponding physical reality. The difference between the two was dramatized in the library scene in  The Day After Tomorrow: the coming of a new ice age had made the tax code fit for burning, but medicine had retained its relevance, as seen when the heroes used a medical book to save one their own (See Figure 1.).

Figure 1. Burning the tax code to survive in a new ice age

In that it affects the physical reality of factories, Lean is more like medicine than tax law. However, besides the absence of consensus on a  BOK, Lean manufacturing differs from medicine is in the role of institutions, and academia in particular. Most medical discoveries are made in university medical schools; nearly all breakthroughs in manufacturing, on the other hand, have been made by self-taught practitioners in factories, with no academic affiliation. I am thinking of high school graduates like Taiichi Ohno, Frank Gilbreth, Charles Sorensen, or Frederick Taylor. Whatever consensus eventually emerges on a Lean BOK, it will not have come from universities. This leaves professional societies and for-profit training companies, and no answer to the question of who certifies the certifiers.

By requiring certifications, company recruiters are making them valuable to applicants, and are generating business both for genuine training organizations and for diploma mills. However, what these recruiters are not doing is their job, because  the next Taiichi Ohno won’t make it past their initial review.

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By Michel Baudin • Management • 15 • Tags: Lean, Lean manufacturing, Management, Six Sigma

Jan 11 2012

IndustryWeek : Manufacturing and Trust: A Prescription for What Ails Our Industry

Via Scoop.it – lean manufacturing
I also wrote on the subject in Chapter 19 of Lean Logistics. Adversarial relationships between suppliers and customers are stable because each side perceives a collaborative attitude with the other as unilateral disarmament: any information they share can be used against them in a future negotiation. And there is no shortage of examples of such fears being justified. So how do you defuse this situation? Rob Olney’s article points the way, but some of his recommendations assume trust is already there. How do you get them to that point?   “Distrust fuels the need for extra time, inventory, paperwork and more, ultimately building more cost and inefficiency into the supply chain.”
Via www.industryweek.com

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By Michel Baudin • Press clippings • 5 • Tags: Lean, Lean Logistics, Logistics, Supply Chain Management

Jan 11 2012

5S – More than just Organization

Via Scoop.it – lean manufacturing

David M. Kasprzak has a different way of saying that 5S is part of the plant’s information system, but I agree.

“If you are only doing 5S to be organized, then, you are doing the right thing – but for the wrong reasons. The point is that you have to embrace visual management.”
Via myflexiblepencil.com

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By Michel Baudin • Blog clippings • 5 • Tags: 5S, Information systems, Visual management

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