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We Speak Lean!

Kaizen-Lean management

Over the last several years Lean Manufacturing (as originally practiced by Toyota as they rose to the largest auto manufacturer in the world) has evolved to touching every type of business. Our own odyssey started when Mark Dover was visiting our supplier of orbital stretch wrappers just outside of Barcelona, Spain and came back inspired by their success to improving our own operations. We started with a self-generated list of about 30 improvements (baby steps!) we could make on our own. That accomplished, we now have teamed up with a professional consultant to dig deep into the process.

It’s been fun, stimulating, a source of opportunity for total team involvement and highly effective. We spent time educating the entire staff from back to front on Lean Principles and plan to enshrine the practice in our culture.

So what does this mean for you? Well, we want to be in a position to be competitive, efficient and, frankly, perfect! Secondly, we have many product and service solutions that can help you achieve your Lean goals.

Speak to us: We speak Lean!

What is Lean? A brief explanation

Lean management

Lean is an organized method for the eradication of waste (Muda) within a system. Lean also looks at reducing waste created through overburden (Muri) and unevenness in work loads (Mura). The popular 5S methodology is often used for implementing Lean.

Principally, Lean is dedicated to highlighting what adds value by cutting everything else. Lean is a management philosophy derived mostly from the Toyota Way, renowned for its focus on improving the flow or smoothness of work to improve overall value.

Getting rid of waste

The original seven muda:

  • Transport — moving products that are not actually required for the process
  • Inventory — all components, work in progress and finished product not being processed
  • Motion — people or equipment moving more than required
  • Waiting — pausing for the next step, production disruptions during shift change
  • Over Production — production in excess of demand
  • Over Processing — resulting from poor tool, process or product design creating unnecessary activity
  • Defects — the effort required to look for and fix defects

Mura and Muri

Mura is inconsistency, unevenness, irregularity or lack of uniformity and its reduction seeks to improve the flow or smoothness of a process. The goal of a Mura based approach is to achieve Just In Time production, by eliminating variables caused by work.

Muri is all the unreasonable work that is imposed on workers or equipment due to poor organization, such as moving things around, dangerous tasks, even working too fast. It is pushing a person or machine beyond its limits.

Muda, Mura, Muri examples

The 5S methodology

The 5S of Lean

The foundation of any effective implementation of Lean is the 5S: Seiri (sort), Seiton (set in order), Seiso (shine), Seiketsu (standardize) and Shitsuke (sustain).

     

  • Sort: Sort out unneeded items
  • Set in order: Have a place for everything
  • Shine: Keep the area clean
  • Standardize: Create rules and standard operating procedures
  • Sustain: Maintain the system and continue to improve it
  •  

5S is a tool for creating a clean, efficient and safe workplace leading to augmented productivity using visual controls and standardized practices.

The Lean Management Model

Lean provides a customer-centric approach used to constantly improve any process through the elimination of waste in all of your endeavours. Lean promotes the notions of Continuous Incremental Improvement and Respect for People.

Take a tour through a Lean environment

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