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May 10 2013

Michelin’s Obsession with Quality | Pete Selleck | IndustryWeek

See on Scoop.it – lean manufacturing

Pete Selleck

“…It’s brand image,” he explained. “There is tremendous value to the perception of trust—customers don’t want to worry about the products they buy; they want it to be trouble free. We can offer them that….

We all use the same equipment to make tire, so we know it’s not the equipment that makes the difference. It’s the interface between the equipment, the material and the person—the training and the qualification of the person—that makes the difference.”

 
Michel Baudin‘s insight:

I see two key statements in this article, both quoted above:

  1. The first is an acknowledgement that the company’s reputation for quality is its crown jewels. It’s priceless, and worth any burden to nurture and protect, and the classical “cost of quality” calculations based on the direct costs of failures, appraisals and repairs are irrelevant.
  2. The second is that the key is the way people work with machines. Selleck does not reference jidoka, but his thinking is in line with it and, unlike the bulk of the American literature on Lean, puts the spotlight on production engineering

See on www.industryweek.com

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By Michel Baudin • Press clippings 1 • Tags: Lean manufacturing, Michelin, Quality, Selleck

May 10 2013

Lean in the Australian bottle cap industry | Foodmagazine

See on Scoop.it – lean manufacturing
“What are the key factors necessary for organisations in the caps and closures industry to successfully drive a lean management initiative? And how can it ensure success and accelerate progress?

The key is to ensure that before program start-up, the organisation’s leaders buy-in to the fact that their lean management program must be viewed from a whole-of-business perspective.”

Michel Baudin‘s insight:

If you have been wondering about the specifics of Lean in the Australian bottle cap industry, the article will disappoint you.

It is a generic discussion about management, strategy, training, and metrics, with arguable points that could be made about any business, from car making to slaughtering pigs and selling insurance. All you would need to do is change the title and the picture.

Without setting foot in an bottle cap plant in Australia, however, it is not difficult to imagine some of the specific challenges the industry faces, like a market of only 23 million consumers spread over an area almost as large as the US.

Given that resin pellets and pigments are less bulky than caps, they are easier to truck around and you might wonder whether this leads the industry to set up many small plants near customers rather than a few large plants.

You might also wonder whether they are delivered to customers as heaps in bins or in sleeves with a controlled orientiation for easy feeding into capping machines…

These are just a few of the questions the article does NOT answer. So why clip it? To successfully implement Lean in a new industry, you need these answers and many others about its management and its technology.

Then you need to work with managers and engineers to not only copy approaches and tools from other indusries, but also adapt them and invent new ones as needed. The article’s authors may have done this, but it is not what they are sharing.

See on www.foodmag.com.au

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By Michel Baudin • Press clippings 0 • Tags: Food industry, Lean management

May 9 2013

Lean dairy farming in New Zealand | The Southland Times

See on Scoop.it – lean manufacturing

“Southland’s dairy farms and economy could reap the benefits of a manufacturing programme designed to increase efficiency in the industry.

The Venture Southland-led Lean Manufacturing Programme focuses on enhancing on-farm performance, reducing input costs and developing the skills and knowledge of farmers by identifying areas where efficiency gains can be made.”

Michel Baudin‘s insight:

Based on the article, it boils down to 5S.

See on i.stuff.co.nz

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By Michel Baudin • Press clippings 2 • Tags: Agriculture and Forestry, Cattle, Dairy, dairy farm, Livestock, Southland

May 6 2013

Top 10 Reason Why Lean Transformation Fails | Tim McMahon

See on Scoop.it – lean manufacturing

“In my experience these are ten reasons why Lean implementation fails:

  1. “No Strategy  […]
  2. No Leadership Involvement  […]
  3. Relying on Lean Sensei/Champion  […]
  4. Copying Others  […]
  5. Thinking Lean Is A Tool  […]
  6. Lack of Customer Focus  […]
  7. Not Engaging Employees  […]
  8. Not Educating Employees […]
  9. Lack of Understanding  […]
  10. Conflicting Metrics […]”
Michel Baudin‘s insight:

Would my top 10 list be exactly the same? Probably not, but there would be extensive overlap.

See on www.aleanjourney.com

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By Michel Baudin • Blog clippings 0 • Tags: Lean implementation, Lean manufacturing

May 5 2013

Big Data – The Antithesis of Lean Thinking | Bill Waddell

See on Scoop.it – lean manufacturing
“It’s too bad lean thinking is free.  I suppose that’s not entirely true; a lean transformation actually costs a few bucks for the learning – consultants, books and training.  But it is nothing like the cost of an ERP system, and it pales in comparison to ERP thinking on steroids – ‘Big Data’.  Because the ERP and Big Data providers play in such a high dollar arena they can and do spend a lot on very focused marketing efforts.  IBM, a company that stands to gain quite a bit from Big Data becoming the focus of business management, is providing “software, curriculum, case studies—including guest speakers” to Rensselaer Polytechnic Institute, Fordham, Yale and about 300 other schools.  Too bad those schools aren’t cranking out kids steeped in lean thinking, but there is no one who stands to make a enough money from peddling lean in a position to buy college curriculums on such a scale…”

Michel Baudin‘s insight:

While I concur with Bill on the irrelevance of “Big Data” in manufacturing, I can’t follow him when he says it is a “singularly bad idea” for business in general.

Big Data, per se, is actually not an idea but a phenomenon experienced in companies like Google, Amazon, eBay, Netflix, and others that process clicks, queries and transactions from millions of users, and generatie Terabytes of data every day. This is what Big Data is. Making sense of it is vital to these companies, and its volume requires special technology.

Even in a large manufacturing company, specs, orders, production status and history, quality problem reports, etc., add up to Gibabytes of data in total, not Terabytes every day. While it is beyond what you can handle on an Excel spreadsheet, it does not qualify as Big Data and does not require the special technology that ecommerce companies have developed.

I also agree that the hot dog example from the HBR blog is simplistic. To give a less trivial example, assume you are in the business of providing streaming videos, and you discover from your customer data that those who view “Tora, Tora, Tora” also tend to view “The Bridges of Madison County.” That is unexpected and you wonder why. Then you find out that the customers who view both are married couples, form which you infer that the wife demands a chick flick for every aircraft-carrier movie…

This is a made-up example, but Ed Frazelle, in Supply Chain Strategy, quotes a real one about on-line ordering patterns for clothing. What kind of garments do customers tend to order together? I have asked that question around, and never met anyone who came up with the right answer, although, once you know it, it makes perfect sense: they order the same garment, in the same size, in different colors. And it is good to know if you are in charge of order picking.

See on www.idatix.com

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By Michel Baudin • Blog clippings 0 • Tags: bigdata, eBay, Enterprise resource planning, IBM, Lean manufacturing, Netflix, Rensselaer Polytechnic Institute, Terabyte

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