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Jun 7 2013

Can’t Always Believe Somebody Saying “Toyota Would Tell You To…” | Mark Graban

See on Scoop.it – lean manufacturing
Mark Graban on LeanBlog: “From my experience, you have to be cautious when somebody says either, “Lean says you should….” or “Toyota would tell you to…” because those statements, even if stated authoritatively, can be wrong.

At a recent speaking engagement (I won’t disclose where), a professor (one who teaches about Lean) made a curious comment that I’d put in the Lean As Misguidedly Explained (orL.A.M.E.) category.

The professor made a point that, when working in healthcare, we have to be careful about applying all methods and tools from Toyota. I agreed with that part of his statement. We’re not literally hanging “andon cords” or putting tape around every piece of equipment just because a factory does it. We have to be solving hospital problems and not just copying tools. I get that.

His example, though, was a bit off base.

The prof talked about “takt time” (or the rate of customer demand) and how we balance the service or production time to match up with takt. Again, that’s correct.

In his hypothetical, he said let’s assume that a doctor’s office is supposed to be seeing a patient every 20 minutes. What if the patient has been in the room for 19:59 already.

The prof said, ‘Toyota would tell you to kick the patient out of the room at 19:59 because you have to keep on takt time.'”

Michel Baudin‘s insight:

The example is about the hypothetical application of the concept of takt time to a doctor’s office. Mark’s post rebuts a statement that it would imply kicking out a patient at the end of the allotted time regardless of whether the patient’s problem was solved.

This is actually what psychiatrists do when they tell patients “Your 50 minutes are up.” But that is because these patients would otherwise linger on indefinitely. At the opposite end of the spectrum, a general practitioner I know who is an excellent diagnostician once explained that she knew what was wrong with 90% of her patients almost the second they walked into her office, and could confirm it within minutes but stayed longer with each patient just so that they would feel cared for and would trust her diagnosis.

In general, however, I don’t see the concept of takt time as applicable in situations where the work content of transactions varies in a way that cannot be anticipated. An MD can’t know how much time a patient will need. Likewise, a maintenance technician cannot know how a long a work order will require, even in preventive maintenance, because you can’t know exactly what you will find when you open a machine.

Incidentally, takt time is not “the rate of customer demand,” first because it is a time and not a rate, and second, because it is not only a function of demand but also of work time available. It is the time that must elapse between two consecutive unit completions at every operation in order to meet demand within the net available work time. It takes 26 words rather than 5, but the definition really cannot be simplified further.

It is an extremely useful concept to plan repetitive sequences of operations done by different people and machines during a shift. But I don’t see much value in applying it, for example, to people who are on call 24×7 to respond to emergencies, particularly when they do it individually. An MD in an office treats a patient end-to-end; it is in not similar to an assembly line, even if patients sometimes feel that way.

There are other approaches to managing such situations. For example, a takt-based approach to computer networks called “token ring” had its day 30 years ago. A token was passed around between computers in a loop at fixed intervals, and only the computer that had the token was allowed to speak while the others listened.

This takt-based approach was abandoned and superseded by Ethernet, in which computers essentially “grab the mike” whenever they have something to say, with a protocol to resolve confilcts when two or more speak at once. It was a better fit to the way computers communicated and is still the basis for your local office or home network today.

See on www.leanblog.org

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By Michel Baudin • Blog clippings 2 • Tags: Doctor of Medicine, Ethernet, Lean manufacturing, Maintenance, Patient, Toyota

Jun 6 2013

Food Processors Must Balance High Throughput With Flexibility | Food Processing

See on Scoop.it – lean manufacturing
“Mass production of food has gone the way of the Model T, and nowhere is the need for line flexibility more important than at copackers. One of the 20th Century’s closing acts was the shuttering of Sara Lee Corp.’s massive bakery in New Hampton, Iowa. It was a brawny, high-volume facility capable of turning out more cheesecake than Americans were willing to buy. Therein was the problem: The plant only excelled at making cheesecake.”

See on www.foodprocessing.com

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By Michel Baudin • Press clippings 0 • Tags: Baking and Confections, copacker, Food industry, Lean manufacturing

Jun 4 2013

Enterprise Ireland and Lean | Irish Times

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“The Japanese are renowned worldwide for their car production where the concept of the management philosophy Lean derives from. It all began at Toyota when the car manufacturers discovered a new, more efficient method of producing cars valued by customers all over the world. The principles learned at Toyota became known as Lean which is claimed can be applied to almost any business. The core principle is creating value by reducing waste and unnecessary risk.”

Michel Baudin‘s insight:

While informing us that the Irish government has an agency promoting Lean, this article reflects common misconceptions.

No, it’s not a “Japanese management philosophy.” it is an approach developed by individuals who happened to be Japanese, which is not the same. Most Japanese today do not know or practice it, and quite a few non-Japanese do.

And this emphasis on “creating value” is an American talking point, not the Toyota Production System.

According to the article “Toyota benchmark themselves constantly,” which is news to me. While it is clear that Toyota is on the lookout for new ideas, I had not heard of Toyota doing benchmarking surveys of competitors. My understanding is that Toyota’s management considers such surveys to be a waste of time.

The article equates Lean with Continuous Improvement, giving the impression that it’s all there is to it.

And finally, the article repeats the Business Week claim that the Shingo Prize is “the Nobel Prize for operational excellence.”

See on www.irishtimes.com

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By Michel Baudin • Press clippings 0 • Tags: Japan, Lean manufacturing, Shingo prize, Supply chain, Toyota, Toyota Poland, Toyota Production System

Jun 2 2013

Article on “Lean warehouse” off the mark

See on Scoop.it – lean manufacturing
“Lean is not just for manufacturing […]; its techniques and tools can be adapted to almost any type of operation. In warehouses and DCs, it can improve efficiency, inventory, safety, and costs, say experts in the discipline. And because Lean changes the way people think about processes and communication, it can be especially effective in helping facilities use warehouse labor more efficiently and cost-effectively. It’s a complex subject that requires formal training to master, but the following will provide a general idea of how lean principles can have a huge impact on warehouse labor.”

 

Michel Baudin‘s insight:

This article is all about the efficiency of warehouse operations and the way “Lean” can reduce warehouse labor. It says almost nothing about the effectiveness of warehouse operations. From this article’s perspective, driving an empty forklift is a waste to be eliminated, but there is not a word about using other means than forklifts to move goods, in perhaps less than pallet quantities, such as carts or small trains. There is not a word either about locating frequently used items in the locations that are easiest to reach, or collocating items that are frequently used together…

At least in manufacturing operations, the number of people used in warehouse operations is a tiny fraction of the number used in production, and increasing their productivity is not the issue. A Lean implementation may instead increase their numbers to improve service and achieve much larger productivity gains in production.

The pursuit of fully loaded forklifts and trucks may increase the efficiency of storage, retrieval, and transportation operations, but also delay e deliveries and hurt the performance of the business as a whole. This is not just my own observations. It has been described as a systematic phenomenon by researchers like Hau Lee.

See on www.dcvelocity.com

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

Jun 1 2013

Car Making in Australia: Welcome to the Lean times | Troy Taylor | Manufacturers’ Monthly

See on Scoop.it – lean manufacturing

Welcome to the Lean times
Manufacturers’ Monthly
So why is Toyota’s management style (A.K.A. Lean management) so different from the others? Firstly Toyota’s system is built on 2 pillars that everyone must promote and follow,.

Michel Baudin‘s insight:

Troy Taylor recounts his experience of working at Toyota in the UK and how it survived and thrived while competitors closed plamts. He sees it as showing the way to Australian car makers.

See on www.manmonthly.com.au

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By Michel Baudin • Press clippings 1 • Tags: Australia, Automotive industry, Lean manufacturing, Manufacturing, Toyota, Troy Taylor

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