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Lean Six Sigma

Manufacturer or Assembler

December 20, 2017

Are you a Manufacturer or Assembler? There are multiple types of manufacturers. Lots of times individuals consider themselves manufacturers when it is possible that they are really assemblers. Every manufacturer assembles goods. Toyota consider themselves to be in assembler. So what is the difference between a company that considers themselves a manufacturing company and a […]

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Lean Six Sigma

Lean Production Classic Failure

December 8, 2017

Lean Production Failure We were working with a company that was very interested in implementing Lean Production. They had partially started on their way by standardizing processes and feeding some employees real-time information. They had about five major products and then some supporting, less complicated products. What they didn’t understand is that Lean Production works […]

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Lean Six Sigma

Sharp Hospitals – Highest Misery Index for ED Performance

November 18, 2017

Sharp Hospitals, in aggregate, perform the worst in San Diego of measured hospitals Emergency Department’s ability to deliver a doctor to a patient. On the misery index, which mimics the pain levels, sharp memorial is a 10 and sharp Grossmont is a seven. Only Kaiser Permanente is between them with an eight. These two Sharp […]

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Lean Six Sigma

Flexible Manufacturing

November 12, 2017

Flexible Manufacturing Definition: The ability to manufacture either at least two products or two models of one product on the same assembly line (preferably at the same time). In most situations it makes sense for a Mass Production environment to embrace Flexible Manufacturing. Mass Production is a department based manufacturing system.  It focuses on each […]

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Lean Six Sigma

Lean Hospitals

October 4, 2017

Lean Hospitals are the hospitals of the future. Hospitals exist in a dynamic environment. Insurance companies pay them, patients rate them, and doctors select them. Hospitals support patients with complex medical procedures and recovery plans but hospitals also still damage patients. Liability issues drive up costs.  There are extensive cost controls in place and increased […]

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Lean Six Sigma

If You Have a Process

September 29, 2017

The world is full of processes. If you are ever going to do something more than once, make it into a process. There are processes such as Emergency Room admittance, surgery set up and Claims process.  The process standardizes the way activities are performed. When the process was first designed the individual or group that […]

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Lean Six Sigma

Mass Production

August 20, 2017

  You are running a manufacturing business and you have found yourself up to your neck in inventory. Inventory costs you money. It depreciates, takes up space, and you must pay to move it. Inventory looks like an asset on your books however, you know that it is anything but an asset. You are running […]

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Lean Six Sigma

Change Drives Excellence

July 18, 2017

Toyota averages one accepted change per employee per quarter. Fujio Cho, a former CEO of the Toyota Motor Company set out to write a book encapsulating the Toyota Production System which Toyota internally calls the Toyota Way. After working on this effort for 10 years he decided that he could not write a static book […]

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Lean Six Sigma

Design of Experiments (DOE)

May 18, 2017

The process no longer generates optimal output, but it used to.  Design of Experiments (DOE) is the solution.  Process inputs are optimized on day one.  But, remember, all mechanical processes degrade over time.  If the Inputs have not changed since the process started, are they still optimized?  You know the output is no longer optimal […]

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Lean Six Sigma

DMAIC

May 16, 2017

DMAIC (Define Measure Analyze Improve Control) Define -The start of the planning and selection process. Overarching Principles • Start Project Charter – perform preliminary work to the best of your capability • Flesh out communications plan and structure Operational Activities • Select team members • Select expertise not on team • Determine schedule (first pass) […]

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Lean Six Sigma

The Winner California Big City

May 10, 2017

Lean Six Sigma works for governments. Ft. Wayne Indiana (Picture 1) implemented Lean Six Sigma a while back. They focused first on supporting their citizens. One example of that was building a web based building permit submittal process. This has a couple of advantages. The first is that the building contractors and homeowners can submit […]

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Lean Six Sigma

Toyota Production System – Hello Lean Production – Part 5

May 8, 2017

Taiichi Ohno came away from the Ford plant with some thoughts. The first was that there was lots of waste littered around the plant. The next thought that followed was that it actually cost less when you make small batches of stampings rather than large production runs.  The Toyota Production System advanced on this seminal […]

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Lean Six Sigma

Value Stream – Walk before Talk

April 27, 2017

You are a CEO and have never walked your Value Streams. Walk before talk.  A company exists to take either material or information and add value to it. The system in your company that creates value is called a Value Stream. It starts with request and ends with product or service. Between those two states […]

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Lean Six Sigma

Who’s Running at 6 Sigma?

April 20, 2017

Airplanes – Six Sigma Airplanes run at Six Sigma.  Do that mean they don’t have failures?  No.  But think about what you care about.  The plane crashing is a failure for me.  Components on planes fail all the time but who cares if the plane still flies and lands.  Six Sigma is a matter of […]

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Lean Six Sigma

Toyota Production System – Goodbye to Mass Production – Part 4

April 17, 2017

Mass Production Prior to and up to 1950 the total production volume of the Toyota Motor Company was 2685 automobiles.  The most efficient automobile factory in the world, operated by Ford, produced 7000 in a single day. This led Eiji Toyoda, who studied every square inch of that Ford plant, conclude with Taiichi Ohno, that […]

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Lean Six Sigma

Statistical Process Control Run Charts – Are They Still Relevant?

April 13, 2017

The Western Electric Company and Lloyd Nelson created elegant and simple rules.  These rules test whether a process is “out of control”.  These helped manufacturers for years to determine the degradation of their processes.  Statistical Process Control (SPC) uses these run charts to derive comfort that their process is stable. Really, violation of these rules […]

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Lean Six Sigma

Manufacturing Statistics

April 11, 2017

Manufacturers run the business using statistics because they give the best metrics for manufacturing performance.  We have listed a summary table of statistical tests here that may be useful for selection of statistical test.  Some are Non-Parametric and others are Parametric.  Some will measure means and others variation.  These are the suite that a Lean […]

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Lean Six Sigma

Toyota Production System – Toyota Emerges – Part 3

April 10, 2017

General Motors has come into play because they out innovated Ford. GM saw a weakness in Ford and that they did not produce cars in different colors. So GM took advantage of this weakness and started to produce cars in multiple colors thereby displacing Ford in many markets. Innovation helps businesses move past competitors.  This […]

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Lean Six Sigma

Lean Six Sigma – Create an Agile Business

April 5, 2017

Competition is stiff and always napping at your heels. Virtually every business has aggressive competitors. Coupled with that is the fact that the market that you are selling to is ever-changing. If you can change as fast as your market, then your business must be managed optimally. Of course, no business could be managed optimally […]

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Lean Six Sigma

Toyota Production System – Mass Production – Part 2

April 3, 2017

Mass Production is the primary accreditation that people give to Ford. However, Ford’s real contribution was not mass production, but what he enlightened saw as the enabler to mass production. In the previous blog, we discussed how all cars during this time period were manufactured using Craft Manufacturing. This was because every part added to […]

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