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Nov 22 2011

News of Lean in truck production in Tatarstan

Via Scoop.it – lean manufacturing

“KamAZ automotive plant has saved 15.8 billion rubles ($526 million) in production expenses by introducing the system of ‘lean production’ since 2006” – Igor Medvedev, chairman of the KamAZ industrial system development committee told the meeting…
Via kazantimes.com

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

Nov 22 2011

Cellular Manufacturing versus Group Technology

Via Scoop.it – Cellular manufacturing

Arif Nurrahman’s article presents Cellular manufacturing (CM) as an application of Group Technology (GT). This is the view of GT experts like Burbidge in Production Flow Analysis, for example, but is at odds with the Lean approach, as explained, for example, in Sekine’s One-Piece Flow, or in Lean Assembly. Group Technology creates product families based on feature similarity, ignoring the demand structure.   The Lean approach is to make it easiest to do what you do most often and therefore starts by classifying products as Runners, Repeaters and Strangers based on demand. Runners are few in number but have a sustained demand high enough to justify dedicated lines. At the opposite end of the spectrum are the many Strangers with low, sporadic demand that you make in a job shop. In-between are the Repeaters, for which you use Group Technology to arrange into families for which you build flexible lines.
Via manufacturers.blognotions.com

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By Michel Baudin • Blog clippings 5 • Tags: Cellular manufacturing, Manufacturing engineering

Nov 21 2011

What is chaku chaku? definition and meaning

Via Scoop.it – Cellular manufacturing
The definition of chaku chaku in the online business dictionary is missing the concept of machines with automatic unloading and incorrectly states that the line must encompass the entire production process, which is not a requirement.

Via www.businessdictionary.com

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By Michel Baudin • Technology, Web scrapings 0 • Tags: Cellular manufacturing, Lean manufacturing, Manufacturing engineering

Nov 21 2011

Chaku-Chaku lines covered in the Manila Times today — When in the US press?

Via Scoop.it – Cellular manufacturing

Chaku-chaku lines are the second generation of cells, allowing a single operator to run15 or even 20 machines. The key concept is for all the machines to have automatic unloading, so that the operator focuses on validating each step through go/no-go gauges and loading the workpiece into the next machine. It’s a concept that deserves more attention than it has received so far outside of Japan.
Via www.manilatimes.net

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By Michel Baudin • Press clippings 0 • Tags: Cellular manufacturing, industrial engineering, Manufacturing engineering

Nov 21 2011

An Alternative to Kanban: One-Piece Continuous Flow

Via Scoop.it – lean manufacturing

This is a guest post by Jim Coplien on Jeff Sutherland’s blog.  Jim’s research seems thorough
Via scrum.jeffsutherland.com

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By Michel Baudin • Blog clippings 0 • Tags: History of technology, Lean

Traffic light

Nov 21 2011

Communication challenges in multilingual organizations

This was a post in the discussion  in the AME discussion group on LinkedIn that Karen Wilhelm prompted with the following question:

Karen Wilhelm: What languages are spoken at your facility? How do you manage the communication challenge? No matter where a factory, or even an office, is situated, there are likely to be several languages spoken by employees. In your experience, how does that affect employee involvement, company culture, daily performance, and safety? What are your strategies for bridging language differences?

Written communication can be addressed more easily than oral communication, by using photographs, drawings, cartoons, pictograms, ideograms and color codes as much as possible. It works, but only as a short term solution: these symbols amount to a new language that the participants need to learn, so you don’t want to overdo it. In the long run, the work force should be proficient and literate in the local language, and you should do what it takes to get it to this point. If you don’t want to make language proficiency a prerequisite in hiring, then you must provide in-house language training.

A good example of a system understood across multiple languages is traffic signals in Europe that contain no words and are understandable to a Lithuanian truck driver on the road in Portugal. This system is easily learned as part of basic driver’s ed. The Chinese writing system is another example that, for over 2,000 years, has allowed written communication among people who speak dialects like Mandarin and Cantonese that are as different from each other as German and French. But it takes 10 years to learn.

Spoken communication in the work place is more problematic because it is more difficult to control. You can’t prevent two operators from using a common native tongue when talking to each other, but it has the effect of excluding third parties, which, immediately causes interpersonal problems and may impact quality, productivity, and even safety. In factories that are foreign transplants, expatriate managers often have discussions in their own language, which accidentally or deliberately keeps locals out of the loop.

While it is reasonable to expect shop floor operators to master English if the plant is in the US, or Spanish if it is in Mexico, you cannot expect them to also learn Swedish because it is owned by a company based in Stockholm. At the management level, multinational companies usually have an official language in which everyone is supposed to be professionally functional. And managers make a point of never using any other language in a mixed group. For example, two Swedes in the privacy of an office may converse in Swedish, but switch immediately to English if an Italian joins them.

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By Michel Baudin • Management 6 • Tags: Management

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