Lean Supply Chain

We’re All in This Together: Teamwork in a Lean Workplace

While some Lean practitioners focus on manufacturing pioneer Taiichi Ohno’s Seven Wastes (transportation, inventory, motion, waiting, overproduction, overprocessing, and defects), many add an eighth waste: behavioral waste, or under-utilized employees. It takes a real change management effort to successfully implement a Lean program—especially when it involves changing workers’ habits. Someone who has been doing a […]

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Reducing Defects and Errors: Don’t Make the Same Mistake Twice

One popular definition of insanity is "doing the same thing over and over again, and expecting different results." So why does that occur all the time in business? Whether it involves producing many items with the same defects, or continuous incorrect inventory counts, we keep shooting ourselves in the foot. Although 85 percent of quality […]

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Are Your Processes Adding Value or Waste?

Packaging helps protect and preserve products, but these days companies tend to over-package and over-protect. Excess packaging illustrates the waste known in Lean methodology as overprocessing. Added processing that doesn’t bring value to goods or services in the customer’s eyes creates unnecessary waste. When trying to eliminate overprocessing waste, start by focusing on standardized work. […]

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Plan Ahead to Avoid Overproduction

Sometimes too much of even a good thing can be bad. Such is the case with excess inventory. Companies need sufficient inventory to meet customer demand, but too much stored product can result in negative consequences, such as high carrying costs. When companies produce or purchase too much inventory, it is often the result of […]

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Playing the Waiting Game

We all want to do our jobs, and are paid to do so. Often, however, we must wait for information or materials from suppliers, supervisors, other departments, and even customers. While we wait, we can get distracted and end up wasting even more time. In Lean terms, waiting is one of the eight wastes. Identifying […]

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Eliminating Wasted Motion

At some point in our careers, most of us have felt we’ve wasted time or effort accomplishing a job that should have been easier, more efficient, and possibly safer to do. One way to help workers make better use of their time and effort is to identify and eliminate sources of wasted motion. In a […]

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Minimizing Wasted Movement

Ideally, material should flow smoothly from Point A to Point B in a process, and be touched only once. That is rarely the case, however. More likely, material is touched and moved many times before its ultimate use. In Lean terms, this excess transportation or movement is waste that occurs when temporarily locating, filing, stocking, […]

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Inventory…What a Waste

We all know that inventory is a necessity. When you fully understand its purpose and cost, however, you realize why lean practitioners consider it one of the Eight Wastes. Inventory can be among a company’s most expensive assets, representing up to half of total invested capital. The major reasons for carrying inventory are to decouple […]

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The Journey to Continuous Supply Chain Improvement

For the past several years, businesses have focused on cutting supply chain and logistics costs. Their efforts have been partially successful, but they have left a lot on the table, not only in terms of cost reduction opportunities, but also productivity and quality. Applying lean manufacturing principles to supply chain and logistics operations is one […]

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