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Tips & Tricks for Efficiently Tracking Lean Projects Recently, we wrote about a couple of problems facing many Lean practitioners. These were problems that hindered their learning process and often caused overconfidence. Amongst the advice to help combat these problems arose the need for detailed tracking and note taking with regards to practice and progress. Being able to accurately track not only the effects but also the process of a Lean project is critical to ongoing success, and is a key to stimulating growth amongst not only the receiving end of your project objectives, but also amongst the employees and Lean practitioners themselves. To start off, let's take a look at the current state of Lean project tracking for many Lean practitioners. A recent LinkedIn discussion posed the very question of project tracking, and sought to understand a few different distinct metrics. In addition to measuring the effectiveness of any program when it comes to completion, tracking can also be about measuring the scope of your projects, so that you can accurately project what the effects will be before you actually reach the stage at which you expect them. Part of this "scope" involves tracking exactly who is involved with your project, who is affected, and how they are progressing in their respective tasks. Where we are now First of all, it's important to evaluate the current methods that are prevalent in Lean record keeping. The LinkedIn discussion starter, self-identified as Ian R., mentions in his opening post that, when he last posed the question about a year ago, the consensus was that most practitioners were simply using excel spreadsheets for their tracking needs. While there's nothing wrong with relying on Excel for the basics, other users were quick to offer up some slicker alternatives, signaling a sharp (and welcomed, in our book) departure from some of the more basic methods. Unsurprisingly, there exist several specialist software applications whose n

I read an interesting article today about safety by Mari-len De Guzman on Cos-Mag.com, an occupational safety e-magazine for Canadian manufacturers. At the CSSE (or, Canadian Society of Safety Engineering) conference in Niagara Falls this week, Los Alamos National Laboratory safety expert, Todd Conklin, spoke about how many manufacturing and industrial companies look at safety issues. He pointed out that, rather than continually blame operator-error for most failures and safety problems, it is more systemic, stating that: workers get hurt when they find themselves in situations where it's hard to be safe and easy to get hurt. With that in mind, he offered several potential causes for failure or safety incidents and ways to combat them. First, he said that humans make mistakes, so he advised that it is important to anticipate those potential mistakes and have several levels of defensive safety measures. Next, he suggested that companies should anticipate that unforeseeable events can happen, and WILL happen, so employers and safety managers need to keep this in mind. Learning is another tip Conklin pointed out. Whenever something bad happens, the best defense next time is to learn as much as we can from the event. We can learn many things, like defenses, unsafe speeds, too much load, proximity to dangerous equipment or products, etc. Finally, he also advised managers to approach safety or failure issues (and the operators involved) with caution. He warned that being positive and asking things in a proactive manner can give a much better reply or response, as follows: Instead of asking a worker, "what have you done, now?" ask them, "how do we set this up so failure doesn't happen again." By asking the right question, employers can get a more operational-centric answer. I really thought this was great info. It might seem like common sense to some, safety matters and needs to be one step ahead of the production line. I also more or less agree with Con

Confined Space Entry Permits - Safety Guidelines Hidden In The Cracks Dangerous, confined spaces are the stuff of horror films and cringe-worthy moments on screen, and there's a reason. Depictions of people trapped in a confined space not only play on a natural human tendency toward claustrophobia, but they also reflect a very real danger in the workplace. As such, OSHA has implemented a system of "confined space entry permits," hoping to help increase worker awareness and avoid common types of injury and death associated with working in a confined space. In this blog post, we'll cover everything from the definition of a confined space, to the details of a fully developed entry permit system. What Is A Confined Space? While the question may seem elementary, OSHA does adhere to strict definitions for confined spaces; this is important to know as a safety professional, as you'll need to be aware of which spaces require you to adhere to OSHA protocol and which don't. Basically, a confined space has to be a place that's large enough for a person to work and perform their job within, but is not intended for long term occupancy by workers. The third and final criteria is that the space has limited means of entry and exit. In short, the space is a place that someone can fit and work in for a limited time, but which impairs mobility and might be difficult to enter and, more importantly, exit quickly. What Is A Confined Space Entry Permit? Sometimes, confined spaces have additional potential risks and hazards that go above and beyond just their shape and size. In these cases, OSHA requires that permits are filed before a worker enters the space. Here are OSHA's additional criteria that indicate the necessity of a permit: The space contains or could contain a hazardous atmosphere The space is comprised of or contains a material that could engulf a worker who enters. The space has any kind of "internal configuration" that might present an additiona

Most writings on voice of customer define it as something like this: An application or procedure that focuses on questions about customers by gathering and reporting results and feedback from them. Furthermore, these are sometimes then compared with other competitors. The problem with most companies' VOC system is that the definition stops there. In reality, there's another whole step that is being cut out. That step revolves around actually taking that research, the observations, and converting them into tangible action. Being able to use your results and make predictive models about the future is the first part of this step, and then taking action to change anything you don't like about what those predictive models tell you is the next part. Finally, you need to monitor how well any implemented changes achieve your goals and actively revise them as necessary. Let's look at these ideas a little more in depth.

When running any sort of physical production based business, you will often have stock on hand. Instead of only stocking for a short time, there will be a "backup" supply of products that can be called upon as demand changes. This is known as "just in case" manufacturing and is highly common in most industries. However, several decades ago, the rise of lean business gave way to the concept of "just in time" manufacturing. In a just in time, or JIT, system, products are made as they are demanded and there is little to (ideally) no back-stock at any time. Why go lean? The idea behind JIT manufacturing is that one can eliminate several kinds of waste by taking away the need to keep inventory of excess stock. From now on, equate "stock" to "excess stock" or the concept of having too much on hand, because in a JIT environment "stock" doesn't really exist outside of individual orders. When you don't have to keep inventory, employees free up their time for other projects and tasks. Also, you have less paperwork to manage, and can focus on other things, like workplace safety, new profitability angles and marketing strategies, etc. Another reason to go to a JIT model is that you increase accountability of management. Because you have no inventory to fall back on in a JIT situation, inventory cannot be used as a crutch to make up for other problems. Slow, inefficient production is often masked by a stockpile of inventory, making it harder to realize certain areas of production may need improvement - these may include machine functionality, worker habits, reliability, and inadequate space management. Another huge place you save by adopting this method is in transportation. Materials do not need to be stocked at various sites and you need to do much less transporting. You will eliminate time wasted in transit when there is traffic or road congestion, and you'll even be more environmentally friendly by reducing fuel burned for shipping purposes

Your facility probably has many written safety procedures-hazard communication or emergency response, for example-but do you have a comprehensive health and safety management system (HSMS)? OSHA mandates many kinds of safety plans, but there is no federal mandate regarding a health and safety system that covers all other safety plans (though some states do require one). This system governs how safety works in your facility and gets everyone involved. If OSHA doesn't require an HSMS system in your state, then why bother implementing one? While a safety system does require a lot of work, the benefits are numerous. Not only will employee morale improve, the number and severity of injuries will be reduced and production may actually increase. Safety, it turns out, is good for business. OSHA also recognizes businesses that have used effective HSMS to achieve lower-than-average injury and illness rates through their Voluntary Protection Programs. Data suggests companies that have developed these kinds of safety systems have seen positive results. According to OSHA: "Companies in OSHA's Voluntary Protection Program, VPP, all of whom have implemented comprehensive safety and health management systems, experience lost workday incidence rates that are 60% to 80% lower than their industry counterparts. They also experience reduced absenteeism and turnover, improved productivity, and lower Workers' Compensation costs. Safety and health management works and adds to the company's bottom line profits." Getting a health and safety system started at your workplace takes a lot of legwork, so let's take a look at how to begin and how to get everyone from management to employees on the work floor involved. Management Leadership Business-Meeting-1 For a health and safety system to be effective, it can't just be left entirely up to a safety manager. Management needs to set the tone for the program and demonstrate their commitment to it by providing necessary polic

The GHS and You - 5 Big Changes April 10, 2014 by Tony Ferraro If your workplace handles chemicals, particularly as the initial producer or as a distributor to clients, it's time to familiarize yourself with the global harmonization system (GHS) of classification and labeling chemicals, or the GHS, for short. What is the GHS? The GHS, first proposed to the United Nations in 1992, is an attempt at bringing some uniformity to the chemical labeling procedures of the developed world. Member nations, based upon their own time-frames, signed on to promise to convert to the GHS method of labeling chemical substances by a certain date. The idea was and still remains to make international business and production easier by having chemical labeling procedures that wouldn't slow down import and export, and would be easy for everyone involved to understand. This also greatly reduces transport costs as materials aren't having to be re-labeled or re-inspected as they cross borders. Last, but certainly not least, the GHS protects workers by ensuring the risks of handling any given material are clearly stated in an easy to understand manner from the beginning. According the UN's publishing of a GHS guide, the following are succinct statements of the GHS' most important goals: Defining health, physical and environmental hazards of chemicals: Creating classification processes that use available data on chemicals for comparison with the defined hazard criteria; and Communicating hazard information, as well as protective measures, on labels and Safety Data Sheets (SDS). OSHA.gov - GHS What does this mean for me? In the United States, the time-frame for adoption is staggered over several stages. On March 2012, the final rule for how workplaces should adopt their policies was published, and employees were required to be trained on these new procedures by December 1, 2013. Interestingly enough, the adoption of the standard by product manufacturers is not required until Ju

If you are planning on purchasing an industrial-grade thermal label printer, you need to weigh several factors. Let's face it, these kind of machines are not cheap-they aren't like the flimsy ones that folks buy to make organizational labels for their home, or for scrapbooking-these are commercial level equipment, and they're designed to hold up to all the rigors of an industrial operation. Pipe Marking Labels So, with that in mind, here are the top 6 factors you should consider before you buy an industrial label maker: 1. Purpose: First off, what do you need to make heavy-duty labels for? Sure, these types of printers can make funny bumper stickers with a catchy slogan on it-but what do you REALLY need it for? Common uses for these are for making lots and lots of pipe markers, arc flash labels, and NFPA 704 "diamond" signs. They're also great for making safety slogans, caution and warning signs, 5S, lean, kaizen, and traffic marking stickers. Depending on how many you need, you might need to use it every day, or for sporadic printings throughout the year. These printers are great, because most of them can print on label tape up to 4 inches wide, and can spit labels out much quicker than those store-bought consumer ones. They can also take the heat and tougher environments of factories and warehouses. 2. Durability: Modern label makers are nearly flawless at their job. They use thermal transfer ribbons and heat seal the text or graphics from the ribbon to a compatible thermal label. This allows for a product that will last for many years before seeing much physical degradation or fading. They are water-resistant and even resist chemical wear. 3. Ease of Use: Many label makers come with their own proprietary software, but I would recommend buying a label maker that can be used with any kind of word processing software or even programs like Photoshop. This way, if you have a change in employees, move offices, or just plain lose the or

GHS Label Information When it comes to labels, few are better known than the GHS labels (even if people don't always realize that is what they are called). GHS, or the Globally Harmonized System, is an international set of standards that are agreed upon to help ensure people from across many industries and around the world are all using universally recognized standards. This includes standards when it comes to the classification and labeling systems used for dangerous chemicals. The GHS labeling standards are used by regulatory agencies as well, including OSHA. While GHS is not itself a legal regulatory agency, most companies are required to follow their standards in this area because of the fact that their standards are adopted by governmental bodies. Common GHS Terms Whether reading GHS labels or making them, it is important to be aware of some terms that are commonly used. SDS - Safety data sheets are required to go along with most GHS labels. These data sheets can provide more detailed information about chemicals and other potentially hazardous materials. Class - Different types of hazards are broken up into different classes. Gasses that are under pressure would be one class. Acids could be another, just to give some examples. Hazard Groups - Hazardous materials are broken down into three groups, environmental, physical and health. Hazard Statement - Hazard statements are standardized to describe specific hazards. These statements give brief but essential pieces of information about the items being labeled. Precautionary Statement - This is a statement that provides instructions on how to avoid dangers when working with these materials. Signal Words - Signal words are DANGER and WARNING. Danger is to indicate a higher level of risk, while warning is for when there is a potential for harm but it is not quite as serious. Pictogram - Pictograms are the visual representation of specific risks. Typically they will just be a black image that is ea

Lean Management - A Guide To Starting Out Right Much like anything over-used and spread before those singing praises have done a lot of research, Lean is a concept that sometimes, despite the best of intentions, misses its mark. Lean principles aren't particularly tricky, but with many offshoots and brands of the ideology, it can be easy for new Lean managers to get caught up in misinformation. At its core, lean is about eliminating all kinds of waste from your business. It sounds simple enough, but one of the biggest problems for many newbies is changing your concept of just what "waste" is. Once you've got a grasp on that, you need to move onto individual strategies that can help you eliminate that waste. In this article, we're going to go over how to accomplish both of these tasks as a manager who may be new to Lean by exploring unique facets of this management type and how they interact with elements of your business. One of the largest differences between Lean management and traditional styles of management is that in a traditional methodology your primary (and nearly sole) concern is the end of the line result. While Lean is of course concerned with achieving superior end results, its focus is on the processes that get you there. In this sense, what you learn and practice as a Lean manager is more about making individual pieces work together efficiently than having a tunnel-vision focus on numbers and figures at the end of the cycle. The Relationship Between Lean management, Waste Elimination, and Continual Improvement "If someone tells you that "lean management is this" and not something else, if someone puts it in a box and ties a bow around it and presents it in a neat package with four walls around it, then that someone knows not of what they speak. Why? Because it is in motion and not a framed picture hanging on the wall. It is a melody, a rhythm, and not a single note." - Lawrence M. Miller, Management Meditations While perhap

When it comes to safety, we all want to do our best and keep our workers out of harm's way. However, wanting and doing are two different things, and governing safety bodies like OSHA are there to make sure that the "doing" part gets done. In fact, OSHA can come inspect a factory or workfloor without notice. While they aren't trying to trick you, they do want to make sure that people who aren't following the rules are caught a bit off guard so that anything that needs fixed can get done before someone gets hurt. In general, if you're doing what you're supposed to and following the rules (and keeping on top of recent updates) you've got nothing to worry about. However, here are a few things you can do to make sure that your visit goes over smoothly and that you get a stellar review from the organization. Do Your Own Inspections One of the easiest ways to prepare is to do your own inspection or have someone come in and do one for you. The point is that it can be easier to catch things and have a unique perspective when actually walking through and putting yourself in the mindset of someone outside of the company, whose sole concern is safety. This kind of thoroughness will trump looking through a safety checklist and thinking "yep, did that one" every time. The other great thing about a mock inspection is that it will condition/get your workers used to having a third party evaluate them and watch them at work, which brings us to… Prepare Your Employees One problem that can come up throughout the course of an OSHA evaluation is employee behavior. Sometimes, being watched can be nervewracking, and for others it can be insulting to have someone glancing in their direction and scribbling something down on a clipboard. In your mock inspections, you can let people know that it's nothing to worry about and that in the event someone does come in to observe, they can just continue working as normal because they're doing everything right already. Ev