For business owners looking for ways to boost productivity and maximize efficiency, 5S and Kaizen are terms that are regularly thrown around, but what is the difference between the two? The two methodologies are some of the most popular and although they can be seen as quite similar, it is important to know the differences before getting stuck in. 5S is a methodology that derives from Japan…
The term poka yoke may sound odd to the average person reading in English, but it is actually a very popular and helpful concept. The term comes from the Japanese language where it was first developed. It is roughly translated to mean mistake-proofing and was first used as a manufacturing idea by the Toyota Motor Company. The ideas behind poka yoke are used in many ways throughout…
You’ve done it! You’ve chosen to start a new 5S program at your business. Get ready for quite the ride with all the improvements that are going to be cascading onto you and your employee’s shoulders as you climb on board with this well-known Lean manufacturing method. Those improvements don’t happen by themselves though, both upper management and employees must work together to make successful and lasting…
The term Kaizen comes from two Japanese words. Kai, which means change, and Zen, which means good. In the manufacturing world, this generally gets translated to mean change for the better, which is the basis for the concept of continuous improvement. Companies that aren’t always looking for ways to improve will find that they are left behind because their competitors are working hard to overtake them. This…
Lean manufacturing just-in-time (JIT) production are two concepts that have quite a bit in common but are actually distinct strategies. Where JIT is focused on improving efficiency, lean looks to take using efficiency to help add additional value to the products that the customer is buying. When used together, these two strategies can provide many important benefits to a manufacturing facility. Learn more about what each of…
5s is the organization of the workplace or a factory that enables the workers to control their work area and eliminate obstacles that hinder work. The 5s factory system originated from the Japanese work culture and is popular in many work places. There are immense benefits of this system and if implemented efficiently, it can help organize, grow and enhance performance tremendously. Here are the basic practices…
With a number of Lean tools at your disposal, it’s important to find the ones that work for your facility. Let’s consider how Gemba, a concept that comes from Lean manufacturing, relates to other Lean ideas. Lean aims to identify and eliminate waste from work processes, ultimately making operations more efficient and less costly while boosting productivity. Waste: Lean Gemba walks fit in well with this mindset,…
Kicking off a 5S program begins with Seiri, or the Sorting step. Unused or little-used inventory and tools hamper productivity, create hazards, and hinder job performance. Industrial facilities and offices alike can get used to clutter and not see the wastes of a disorganized space. In reality, excessive tools and materials can impede workflow as employees have to spend more time looking for the item they need,…
At its core, kaizen is a group effort. Only when the entire organization embraces the ideals of kaizen will you see its benefits. The dedication to kaizen must start at the highest level of management and must infect middle management and the general workforce like a virus. Kaizen will forever change the manager-worker relationship. Traditionally, the manager’s role was to plan, implement, and supervise the workers. But…
A workplace where employees or visitors can easily understand how an area operates based on signs, labels, and other visual cues is often referred to as a visual workplace. These cues can include placards on walls and/or machinery showing operating procedures, equipment labels, signs with important reminders, and inventory level markers, as well as floor markings. Most large, profitable manufacturing companies have created visual workplaces, as visuals…