Last Updated on Friday, 01 January 2010 21:20 Written by Administrator Thursday, 22 October 2009 22:33

First, a disclaimer. None of us at Leonardo Group Americas have worked at Toyota, or have received any training directly from them, nor do we use many Japanese words in our Lean practice. What we know is based on our 20 years of Lean experience, combined with an active review of available information and books.

That said, it is clear that much credit for the development of Lean is given to the Toyota Motor Company, arguably the most successful company in history. The methods and tools of Lean have been adapted successfully in many other companies and industries, and there is also a growing wave of interest in applying these methods in non-manufacturing environments. There is, however, one little catch. No one in the world has been able to duplicate fully the success of Toyota. Mountains of books have been written and millions of hours have been expended in attempting to copy the Toyota model, without complete success. Benefits are many, of course, but nobody has been able to copy the recipe completely.

As it turns out, along with the visible elements of Lean there is a hidden and secret world: the culture of relentless pursuit of continuous improvement, a culture or way of behaving that we cannot see with our eyes. Up to now people have focused mainly on the external elements and tools of Lean, including flow and pull systems, kanban and kaizen.  The hidden habits of excellence, driven unwaveringly from the top of the organization to the entire workforce, are difficult to see, and what are most often lacking in other companies.  What you think about Lean is probably wrong.

Here's an example: it is usually considered prudent to take Murphy's Law into consideration, and when designing a line or cell allow for some flexibility in case something goes wrong. We may, for example, have multiple routings for products, so that the same product can be built on multiple machines in case one should go down. If our prime objective is to "make the schedule", then this method is good. If our prime objective is process improvement, then this method is bad.  Apparently at Toyota they are not allowed, because it makes it more difficult to unearth and identify production problems.

We at Leonardo Group Americas have condensed the “hidden” culture of Lean, as it applies to any business environment, into a 45-minute eye-opening and provocative webinar, and we invite you to attend. This webinar is based on recent developments in the understanding of how Toyota actually works, and our extensive experience implementing Lean in hundreds of companies and industries since 1994. Be prepared to have your preconceptions challenged, and for your idea of what Lean is to be changed forever. Click on the link below to find a date that works for you and register.

Last Updated on Friday, 01 January 2010 21:23 Written by Administrator Friday, 18 September 2009 20:58

Leonardo Group Americas is pleased to announce a new, 60-minute webinar on Lean Manufacturing, based on our growing series of LeanRoadMaps®.  This webinar is tailored for those who may be new to Lean principles, or who are considering starting Lean projects in their own organizations.  In addition to explaining the well-proven Lean Roadmap methodology developed by Leonardo Group Americas, the webinar covers the actual steps of a successful Lean project, from Value Stream Mapping to measurable outcomes.  Finally, three recent case studies of LGA engagements illustrate just how dramatic Lean improvements can be.

Webinar participants will also have a chance to ask questions of the live presenter, a Senior Lean Consultant with Leonardo Group Americas.  You can view the available webinar dates by clicking on the link below, and register online.  Presentations are limited to only 30 participants, and our webinar sessions have been filling up, so register early. We look forward to your participation!

At Leonardo Group Americas we have developed a set of flow-charts, called LeanRoadMaps®, that document the step-by-step process of Implementing Kanban, developing a kanban system, creating kanban cards and performing kanban calculations. Kanban is a powerful and essential element of Lean and Flow Manufacturing.  By clicking on the link below you will have the opportunity to download the "Vision Map" for Implementing Kanban. We just need your email address and name.

We are also offering a 60-minute webinar on Implementing Kanban, explaining in detail the step-by-step Kanban implementation process. You will also have a chance to ask questions of the live presenter, a Senior Lean Consultant with Leonardo Group Americas. You can view the available webinar dates by clicking on the link below, and register online. Presentations are limited to only 15 participants, and our webinar sessions have been filling up, so register early.

 Leonardo Group Americas LLC is a member of the Lean Factory Group, along with Bosch Rexroth, Bosch Production Tools and Orgatex. Over the coming year, Lean training and simulation events will be conducted across the US. These road shows highlight the importance of a data-driven approach to lean implementation, the need to create an environment that supports lean with the right tools and equipment, and methods and tools for the creation of a visual factory. You can visit the Lean Factory Group website by clicking here.