PT Ganesha Abaditama’s Post

With an understanding of Yokoten, you can enhance your approach to lean manufacturing by effectively sharing knowledge and best practices across your organization. This Japanese term, "horizontal deployment," emphasizes the importance of spreading successful solutions from one area of your operations to another. #Communication #ContinuousImprovement #LeanManufacturing #visualmanagement

Yamazumi is a Japanese term that refers to a method used in production planning and scheduling, particularly in lean manufacturing environments. It involves the balancing of workloads across different processes or workstations to achieve optimal efficiency and productivity. The goal of Yamazumi is to eliminate bottlenecks, minimize idle time, and ensure smooth flow throughout the production process. It often involves visual tools such as charts or diagrams to help managers and workers understand the distribution of work and identify areas for improvement. #lean #waste #yamazumi #takttime #voc #vob #production #6sigma #kaizen #continuousimprovement #iyileştirme #yalın

With an understanding of Yokoten, you can enhance your approach to lean manufacturing by effectively sharing knowledge and best practices across your organization. This Japanese term, "horizontal deployment," emphasizes the importance of spreading successful solutions from one area of your operations to another. #Communication #ContinuousImprovement #LeanManufacturing #visualmanagement

5G of Gemba, Gembutsu, Genjitsu, Genri and Gensoku. Part 4.1 Genri & Gensoku. In brief, 1. Genri delves into the underlying theoretical principles of a process or system, and 2. Gensoku provides practical rules, standards and parameters for consistent and reliable performance. In details, While both Genri and Gensoku are principles that play important roles in guiding actions and decisions within a process or system, they have distinct differences: Genri (原理) - Fundamental Principles Definition: Genri refers to fundamental principles or theories underlying a process or system. These principles are often based on scientific or engineering concepts and provide the theoretical framework for understanding how things work. Focus: Genri emphasizes understanding the "why" behind a process or system. It delves into the underlying principles and theories to provide a deeper understanding of the mechanisms at play. Example: In manufacturing, the principle of "lean production" is based on Genri principles such as minimizing waste, optimizing workflow, and continuously improving processes. Gensoku (原則) - Standard Rules Definition: Gensoku refers to standard rules, guidelines, or principles that govern a process or system. These are established norms or best practices that dictate how tasks should be performed or how operations should be conducted. Focus: Gensoku focuses on practical rules and standards that provide a framework for consistent and reliable performance. These rules are often based on experience, industry standards, or regulatory requirements. Example: In a manufacturing setting, Gensoku may include standard operating procedures (SOPs) for equipment operation, safety protocols, quality control measures, or compliance regulations. #leadership #management #innovation #creativity

The Stove x The Microwave: Great reading from Lean Enterprise Institute. Jidoka is a powerful principle and separating human work from machine is key part of it. When cooking on a stove, constant attention is required, whereas with a microwave, you can start the process and move on to other tasks until it signals completion. This analogy highlights the potential for efficiency improvements in various operations, not just in manufacturing but across entire processes. It's a powerful reminder of how often workers have to press a button to activate a machine but still need to be present to monitor or assist. Implementing Jidoka can transform this scenario, allowing human workers to focus on more value-added tasks. Read the full article here:

==== Host a learning-by-doing workshop on Job Shop Lean ==== If you are a high-mix low-volume manufacturer, especially a machine shop or fabrication shop or similar manufacturer of discrete products in a facility with a Functional layout, would you like to host an onsite pro bono Job Shop Lean workshop? HOW TO IMPLEMENT LEAN PROJECTS THAT QUALIFY AS KAIKAKU OR KAKUSHIN.......AND NOT JUST KAIZEN Kaizen = Change + Good = Change for Better, Continuous Improvement Kaikaku = Change + Revolutionary = Radical Change, Transformation Kakushin = New + Revolutionary = Innovation, Reform, Renewal[1] 3 days! Onsite! Pro bono! It will address ***your*** operational challenges that come from being a high-mix low-volume manufacturer! No bs (else you can knock me silly with my own book --- it is a Weapon of Mass Concussion if swung around indisciminately)! IMPORTANT: Prior to the onsite workshop, you must send me a PFAST Input File for your product mix. I will input it to PFAST, generate the outputs, cut-and-paste them as appropriate, identify candidate projects that could be discussed during the onsite event and, most importantly, have you determine which of those candidate projects you would like to discuss during the workshop. [1] Source: https://lnkd.in/gkhm9SJU

The 5S is part of the Lean method developed by Toyota in Japan. Originally aimed at increasing labor productivity, it was quickly recognized 5S also improved quality management and work safety. Junnikkala's 5S project was launched in Kalajoki and Oulainen units at the beginning of 2023. The change in working methods has led to significant progress. At the Oulu production unit, the 5S method was introduced this autumn. The basic pillars of 5S are: ✅ Sort ✅ Set in order ✅ Shine ✅ Standardize ✅ Sustain The 5S method helps to ensure that only the necessary equipment is present at the workstations. It also helps to solve material storage problems and to study the flow of material through production. Systematization helps to set rules and standards about where equipment is stored. Standardization helps to harmonize working practices according to best practices. Regular monitoring ensures that new procedures and practices are sustained. #5s #junnikkala #worksafety #growingstrong #qualitycontrol #sustainablegrowth

What is 6S? What are its benefits in manufacturing industries? 6S is a lean manufacturing technique that stands for: 1. Sort (Seiri): Remove unnecessary items 2. Set in Order (Seiton): Organize and categorize items 3. Shine (Seiso): Clean and maintain the workplace 4. Standardize (Seiketsu): Establish standards and procedures 5. Sustain (Shitsuke): Maintain and continuously improve 6. Safety (added later): Ensure a safe working environment Benefits in manufacturing industries: 1. Improved productivity and efficiency 2. Reduced waste and inventory 3. Enhanced employee morale and engagement 4. Better quality control and reduced defects 5. Improved safety and reduced accidents 6. Reduced lead times and improved delivery performance 7. Improved communication and teamwork 8. Reduced costs and improved profitability 9. Improved customer satisfaction 10. Continuous improvement and innovation By implementing 6S, manufacturing organizations can create a more organized, efficient, and safe work environment, leading to improved performance, quality, and customer satisfaction. #6S #Industrialengineering #kaizen #kanban #processimprovement #production #quality #improvement #adidas #textile #manufacturing #excellence

Go to Gemba. Look at the Gembutsu. The book "Gemba Kaizen: A Commonsense Approach to a Continuous Improvement Strategy" by Masaaki Imai was first published in 1997. It has since become a renowned work in the field of continuous improvement and operational excellence. There are three key elements we should practice in the Gemba or the work place as we look at the Gembutsu - the actual product or process. 1. Observe closely - spend time in the shopfloor, warehouse or work area. Observe the processes, workflows, and interactions. 2. Ask questions by engaging with the people to understand nuances and variations. 3. Document findings - notes, photos, flow charts. Now, while designing digital solutions prioritize the end customer using the above steps. This is critical if you want full adoption of the new tools and a successful transformation. Design the solution keeping the use case front and centre - beyond managerial inputs and IT decisions. Resonate with the end user. If the first attempt does not succeed go back and get the voice of the customer once again. These three timeless steps should be the foundation of your Business Requirement Document. Stay committed to the process. Thoughts and differing opinions are welcome. #Continuousimprovement #manufacturing #digital

One of my favorite things to do when starting any new project is to do a #gemba. If you are not familiar with lean manufacturing: gemba is a Japanese term that means "actual place." A gemba walk is going to the actual place to see how work is actually done - starting where you are. The most important things to remember when taking a gemba walk is to lean into curiosity and to show respect. You are there to understand what is currently happening without judgement and to record what you see. You can then use what you have seen to find areas in the process to make improvements. I try to only ask questions that need to be answered with more than a yes or no rather than make statements and always strive to acknowledge that the frontline workers know more about this process than I do. I am there to learn from them not to show them how much I know. Where have you used gemba? What are your favorite ways to start a project? #PEOPLEIT