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Mar 30 2014

The Discovery of Lean | Narrated Prezi by Mark Warren

See on Scoop.it – lean manufacturing
Brief description on the origins of lean. Lean is an outcome of implementing Flow Principles + the TWI program

 

 

 

 

Michel Baudin‘s  comments:

This is a short version of a one-hour presentation I heard live a few months ago. Mark’s take is the result of more than 30 years of practical experience in all sorts of plants around the world and more than a decade of intensive research of original documents in numerous archives in several countries.

To understand where concepts and techniques are useful in manufacturing today, we need to know who invented them and for what purpose. The historical perspective is not a luxury, and the explanations of this history must be accurate if it is to enlighten us.

At historical research, Mark is a pro; I am an amateur. John Hunter thinks I have a “library full of dusty tomes.” In truth, I only have a few old books on manufacturing, half of them recommended by Mark.

See on prezi.com

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By Michel Baudin • Blog clippings • 2 • Tags: Flow, Ford, History, Lean, Mass Production, Toyota

Mar 27 2014

Is it a Bad Idea to Pay a Lean Consultant Based on a Percentage of Cost Savings? | Mark Graban

See on Scoop.it – lean manufacturing
Blog post at Lean Blog : The price paid for most management consulting work is based on either a daily rate or some variation of a flat-rate fee based on what is being delivered. Enterprise software pricing is also often fixed. In both cases, the client pays this with some expectation of benefits and even an “ROI” for the customer.[..]

Michel Baudin‘s comments:

I agree with Mark, and I am happy when clients report that they get ten times in benefits what our services cost. A daily fee for work done on site and a fixed fee for deliverables for offsite work are simple arrangements; paying a percentage of benefits, whether cost savings or revenue increases, is a complicated arrangement, conducive to misunderstandings and disagreements.

See on www.leanblog.org

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By Michel Baudin • Blog clippings • 0 • Tags: consulting business, Management

Mar 23 2014

Renault: An international school of Lean Manufacturing opens at Flins | Automotive World

See on Scoop.it – lean manufacturing
“Jose-Vicente de Los Mozos, Executive Vice President, Manufacturing and Supply Chain, of the Renault Group, inaugurated the International School of Lean Manufacturing yesterday.”

 

 

Michel Baudin‘s insight:

When I visited this plant in 1994, I never imagined that it would be the site of an international school of Lean 20 years later.

We were working at the time on Lean implementation with CIADEA, the Renault licensee in Argentina. It had originally been a subsidiary, was sold to local entrepreneur Manuel Antelo in 1992, and was repurchased by Renault in 1997.

At the time, my hosts in Flins thought that Lean was just a way to cut heads and that implementing 5S would cause production to drop.

Times change.

See on www.automotiveworld.com

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

Mar 20 2014

Is it Lean’s Fault or the Old Management System’s? | Mark Graban

See on Scoop.it – lean manufacturing
Blog post at Lean Blog :

“[…]The problem is the culture doesn’t change overnight. Leaders have years or decades of old habits (bad habits) that run counter to Lean thinking. They might be (might!) be trying to change, but people will still fall back into old habits, especially when under pressure.

I hear complaints (in recent cases) coming from different provinces in Canada that say things like:

Lean is causing hospitals to be “de-skilled” by replacing nurses with aides. Lean drives a focus on cost and cost cutting, including layoffs or being understaffedLean is stressing out managers by asking them to do more and taking nothing off their plateNurses hate Lean because they aren’t being involved in changes[…]”

Michel Baudin‘s comments:

In this post, Mark Graban explains how the leadership in Canadian hospitals is slapping the “Lean” label on ancient and counterproductive “cost-cutting” methods, and how the victims of these practices unfairly blame Lean.

This is definitely L.A.M.E., Mark’s apt term for “Lean As Misguidedly Executed,” and is found in Manufacturing as well as Health Care. Much of the article — and of the discussion that follows — is about what I call yoyo staffing: you hire more than you should in boom times, and lay off in recessions.

Of course, it isn’t what Toyota did, and churning your work force in this fashion not only disrupts people’s lives but is bad business. Hiring, training and firing repeatedly prevents your organization from accumulating the knowledge and skills it needs.

Mark makes the case that Lean should not be blamed for mistakes that have nothing to do with it. Other than raising consciousness, however, the post does not propose solutions to keep this from happening.

While there have been studies published on Toyota’s approach to Human Resources (HR), I don’t recall seeing much in the American Lean literature on topics like career planning for production operators.

In his comments, Bob Emiliani paints the current generation of leaders as “a lost cause,” and places his hopes on the next. He seems to suggest that the solution is to wait out or fire the current, baby-boomer leadership and replace it with millenials. I don’t buy it and, deep down, neither does Bob, because he ends by saying “While one always hopes the “next generation will do better”, it could turn out to be a false hope.”

Like everything in HR, generational change has to be planned carefully. The people who rose to leadership positions presumably did so not just because of bad habits but because they also had something of value to offer. And the way the baton is passed is also a message to the incoming leaders: it tells them what to expect when their turn comes.

See on www.leanblog.org

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By Michel Baudin • Blog clippings • 2 • Tags: Health care, Human Resources, LAME, Lean, Manufacturing

Mar 18 2014

A Definition of Lean | Mike Rother

See on Scoop.it – lean manufacturing

Maybe it’s time for a better definition of “Lean.” Here’s one for you to consider and build on.

Michel Baudin‘s comments:

The proposal is “Lean is the permanent struggle to flow value to one customer.”

Permanent struggle is fine, but I prefer pursuit. It means the same thing but it is shorter and “pursuit of happiness” sounds better than “permanent struggle for happiness.”

On the other hand, I have a problem with “flow value,” which I see as the sort of vague abstraction that would prompt Mike Harrison to ask whether it come in bottles. It is exactly what Dan Heath is warning against in the video included in the slideshare.

I also have a problem with the exclusive focus on customers, which I see as Business 101 rather than Lean. Lean includes many features like heijunka, that are intended to make life easier for suppliers and are transparent to customers. Going Lean means looking after all the stakeholders of the business, not just its customers.

This is why I define it instead as the pursuit of concurrent improvement in all dimensions of manufacturing performance through projects that affect both the production shop floor and support activities. 

Yes, I know, it is specific to manufacturing, but that is not my problem.

See on www.slideshare.net

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By Michel Baudin • Blog clippings • 4 • Tags: Lean, Mike Rother

Mar 17 2014

Averages in Manufacturing Data

The first question we usually ask about lead times, inventory levels, critical dimensions, defective rates, or any other quantity that varies, is what it is “on the average.” The second question is how much it varies, but we only ask it if we get a satisfactory answer to the first one, and we rarely do.

Continue reading…

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By Michel Baudin • Data science • 8 • Tags: Average, Bill Gates walks into a bar, Critical Chain, Deming, ERP, Goldratt, mean, median, typical value

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