Welcome to Part 1 of a 5-part series on Lean Design. You would not expect to build a house without a good set of drawings and a design, and likewise you should not expect to achieve high-performing business processes without a formal design. A “Lean Design” implies that the process or processes will be extraordinarily efficient, free of waste, able to produce high quality, and meet the designed capacity goals.
A few years back, I attended a talk by the CEO of a major manufacturing company. He shared with us that his company had conducted 600+ Kaizen events in the previous 3 years. Unfortunately, at the end of that time, when he looked at the P&L, it was hard to see where all of that effort went. Sad!
"Kanban doesn't work in my factory." This is one of the most common objections I hear to the Mixed Model methodology. You know what? Sometimes it's true. So what do you do when kanban fails?
How can one simple Material Management change free up six million dollars of cash?
In my 20+ years as a Lean consultant, I've found that there is one issue that more factories have difficulties with than any other: Material Management.