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Lean Articles

One week at The Ohio State University campus…

Lean Manager Certificate Program dedicated to the service industry and support services This week at The Ohio State University campus was the last week of our Lean Manager Certificate Program dedicated to the service industry and support services …
LMAC SERVICES - 3rd week

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The Use and Abuse of OEE

Overall Equipment Effectiveness (OEE) is fast becoming a widely used measure for the manufacturing industry, but it is also one of the more misunderstood and misused measures, causing much confusion...

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A Maintenance Miracle

Autonomous Maintenance is a powerful technique that can eliminate between 40% - 60% of unplanned downtime. Autonomous Maintenance is the focus of our Maintenance Miracle Kaizen event. The article below provides insight from a past event we held at Acushnet’s Ball Plant III.

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Quantum Leap Yield Improvement

Production Preparation Process (3P)—Milestone 13
In the highly competitive world of vinyl siding production, “process yield is king.” A fraction of a percentage point change in yield traditionally is very difficult to attain let alone sustain. So you can imagine what was going through one plant manager’s head when he got the news that yield had to improve 2.4% above last year’s performance.

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Tag That Attitude!

We were recently contacted by one of our clients to convey how their TPM efforts were progressing… Can you pick out the most important thing?

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Engaging your Workforce

Operational excellence, continuous improvement, lean management—no matter what you call your pursuit of perfection, in order to sustain it employees have to be “engaged".

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Developing TPM

Absent TPM, the Lean Enterprise Doesn't Happen.
Developing a strategy to establish TPM – and integrate it as part of a lean transformation – begins with analyzing and understanding the key areas that need to be improved throughout your operations. 

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Lean Lessons At the Movies

Quoting movie dialog is a big thing in my family.  I am not sure how it started, but we do it often.  Last week at a SMED training session, an attendee was reeling off movie lines to his team members.

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The Improvement Strategy “Trinity”

In a memorable scene from the movie “Raiders of the Lost Ark,” one of the bad guys challenges Indiana Jones to a sword fight. As the challenger brandishes his sword in preparation for battle, Indiana sizes him up for a moment, then just pulls out his gun and shoots him. Duel over.

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Invest for Success

I shared this experience with some of my contacts earlier this week, but wanted to post it here as well as it might be of use to some of our readers…

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Can you solve the same problem twice?

Recently I was working with a project team looking at machine data for a key piece of equipment.  The data showed the machine had several sporadic losses in that particular week.   To dig deeper into the data, we spoke to the operators and maintenance staff; one seasoned associate told us, “Oh, I know what caused that loss, we’ve had to fix that a few times.”...

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Beyond the Improvement Strategy

Recently we were invited to help a metal manufacturer with two business units and several production facilities address the issue of their continued under-performance; despite what the company felt was a herculean effort to drive cost from their system.

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The Big Miss·take

The ‘big miss’ in golf terms refers to a bad golf shot, one from which the player cannot recover par.  I was reminded the other day about another type of ‘big miss’, this one occurs in the workplace rather than on a golf course.

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