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Ten Tips to Help You with Your Kaizen Continuous Improvement Strategy The Kaizen methodology encourages ongoing efforts to ensure continuous improvement throughout a facility. This improvement can come in many forms including waste elimination, improved efficiency, safer work environments and much more. To simply say that a facility is employing Kaizen strategies, is essentially meaningless if you don't have any concrete action items you are following. Whether you're just getting started or you are looking for ways to reinvigorate a Kaizen strategy that is not effective, the following ten tips will be very helpful. Each one can give you ideas on what you can do encourage improvement and allow that improvement to grow and expand long into the future. Tip #1 - Harness the PDCA Strategy One of the key concepts used in Kaizen is the "Plan-Do-Check-Act" strategy. This is a quality model that can be used when implementing any type of improvement in the facility. As you might expect, the PDCA strategy is a cycle of ongoing improvement that should never end. The steps are as follows: Plan - This step is where you identify an area where improvement is possible and make an initial strategy on what chance should be made to realize the desired improvements. Do - Implement the change, but only on a small scale. This may mean having one department make the change in some situations or for larger corporations, having one facility make the update. During this step it is also very important to be gathering as much data regarding the change so it can be properly evaluated. Check - Review the results of the change including the data that was collected. Looking to see if they had the desired impact or not is critical to know whether you should move forward with rolling the change out to other areas. Act - IF the data in the check step points to a success, it is time to push the change out on a wider scale. Once the change has been successfully implemented you wi

Lean systems are meant for producing the best products and services with little or no wastage of various kinds of resources. Lean supply chain management purports to create a well designed supply chain management system where all the resources are effectively utilized. The people, processes, technologies and suppliers will be optimized at the beginning of the implementation and it will be an ongoing process. The best of the best features will be implemented and there will be no room for waste. Lean supply chain helps companies deliver high quality products quickly and efficiently. What is expected from lean supply chain management? In fact, lean supply chain management is a new way of thinking to understand the supplier networks. It is required to have cooperation with various suppliers and should be able to balance it with the competition present in the market. There is a great deviation between lean supply chain management and traditional methods. There will be less number of structures in lean model whereas they are more in traditional systems. Most of the lean supply chain management principles are derived from the basic lean principles. How companies will be benefited by the lean implementation? By implementing lean methods in a systematic way, companies will be benefited to the greatest possible extent. The winning business strategy realizes the importance of the relation between the supply chain management and the overall financial status of the company. By streamlining the supply chain management with all the other core aspects of the company, the business will emerge into a profitable enterprise and will be able to deliver cutting edge solutions. Strategy for lean supply chain management In order to implement the lean supply chain management in an effective manner, it is required to build the core infrastructure and should be collaborated internally and should be executed externally as well. The next step would be the selection of the right kind of

According to the Insurance Information Institute, 40% of businesses affected by a natural or human-caused disaster never reopen. When disaster strikes, consumers can only wait so long before moving on to another supplier or service provider if you are not able to get operational in time. Insurance might help to recover some of your loses, but it will do little to replace your customers. More importantly, the safety and well-being of your employees as they cope with disaster is a hefty task in itself to take on. In light of recent events, many organizations are left wondering, are they ready and prepared when disaster strikes? So just what does it mean to be ready? Investing in a preparedness program can make all the difference in the world when disaster strikes and promote an internal belief that your company is ready for disaster when it strikes. This policy should reflect the mission and values of your organization that can be implemented seamlessly throughout the company. Focal points of your preparedness program should detail specific goals including: The overall safety and protection of your employees, visitors, and any other persons that may be at your facility when a disaster occurs. Don't forget to account for persons with disabilities and special needs. Keeping customer service operations functional Protection of assets, both in the physical and electronic form Environmental protection and contamination prevention Companies image and reputation Having a team to help continue the improvement and implementation of your program is vital to its success when needed. Your team should meet regularly to continue the development and focus of the program. Each individual will have their own role and responsibilities when disaster strikes, a proper preparedness program will identify these, insuring an accountable team to help in the recovery process. How do you know what to plan for? It's impossible to predict what the next disaster will be, but accounting f

Occupational Safety and Health Administration or OSHA is a body created in the year 1970 by the American Congress in order to protect the workers from being harmed or injured in the workplace. This entity implements rules and standards that will enforce health and safety of the workers. With this, working in companies that are OSHA compliant can give you that sense of security. But what are these standards and how they are implemented? OSHA Regulations There are two kinds of regulations being handled by OSHA and these are health standards and safety. The former deals with toxins exposure and the outcomes of other hazards while, the latter deals accident prevention. Some of the rules being implemented by this organization were actually adopted from private agencies. OSHA was supported by other bodies such as the NIOSH or National Institute of Occupational Safety and Health in the creation of the laws. OSHA compliance can be very advantageous since it boosts workers productivity knowing that the company can provide better care. With this, employers must devote time to come up with a safer work area. OSHA - Protection to Workers Employees have the right to work in a safe workplace regardless of the industry they work in. Hence, if you think that the company you are working with has violated the rules you have the option to file a complaint at to OSHA. With your report, they can conduct inspection on your workplace to determine whether your employer is OSHA compliant. In essence, OSHA gives employees the following rights: Request OSHA to inspect the work area - This can be done if your employer has violated the laws on operating heavy machineries such as forklifts and failed to provide an area such as eyewash facilities for employees who are working with corrosive substances. Even the failure to comply with the safety floor markings is subject to OSHA's investigation. Practice their rights - OSHA safeguard the right of workers so that they can exercise the

In the past decade, cell phone usage while driving has sprang up as a major driving safety issue in the United States and many other developed countries. Originally, teens were the primary target of anti-texting and driving campaigns, but now that cell phone usage is standard amongst a multitude of demographics, the issue has become more broad and is impacting a larger population. According to OSHA's page on Distracted Driving: The human toll is tragic. DOT reports that in 2009, more than 5,400 people died in crashes linked to distraction and thousands more were injured. "Texting while driving" has become such a prominent hazard that 30 states now ban text messaging for all drivers. OSHA - Distracted Driving From checking Facebook, to making phone calls, to checking in with friends and loved ones via text, cell phones have become distracting in the workplace as well, and many companies have, in recent years, implemented cell phone policies on usage to help to maintain productivity. Just like with regular driving, however, cell phones also present a safety risk to workers on the job, especially when machinery and vehicles are being used. In this blog post, we're going to cover various aspects of cell phone workplace safety with regard to work sites. Cell Phone Workplace Safety and Transportation Many of the most problematic workplace instances of cell phone distraction, just like in the rest of the world, come from those who are constantly driving. In your company, this might mean that a delivery truck driver gets distracted and hurts a worker on their way in or out of your warehouse, or it could mean that they injure a civilian or damage someone's property while out on a delivery. Either case you want to avoid, and with damage or injuries to outside parties, you have even less coverage (no worker's compensation, etc.) than if you had an incident contained to workers and company property. The best way to void these distractions are to set hard rul

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

Lean Six Sigma for Non Profits We always like to hear about people applying business methodologies and mechanics in arguably unorthodox ways or markets, and today I stumbled across a LinkedIn discussion that happens to exemplify exactly that sentiment. User William Falquero seemed to be onto something interesting as he posed a question for other professionals: Could non-profit organizations benefit from Lean Six Sigma thinking? If so, how would they be implemented, what would the challenges of this sort of endeavor be? Only a few users jumped in right off the bat, but, lucky for our purposes today, they were some critical thinkers with some useful insight and examples to offer up. Today, we're going to take an in-depth look at the use of Lean and Six Sigma thinking and tools within non-profit and charity organizations. Are Charities Good Candidates for Lean? One of the first and most important things to establish when considering implementation of Lean in any company or organization is to figure out how they could benefit from the systems. In the case of charities, one user points out that room for improvement from Lean is readily apparent simply in the mindsets of the people who work at them: "The sweat and tears the non-profit workers and volunteers shed and the effort they put forward is focused on those they serve, with less thought on HOW they are served" This is what Richard Petty had to say of an organization he actually had the experience of implementing Six Sigma with. One thing he goes on to highlight and elaborate on is the fact that many volunteers and non-profit workers are so focused on those they want to help that they may get blinded as to the mechanisms that can take them there (and these are the places opportunities for improvement present themselves). Even in other more traditional workplaces, we see this sort of "tunnel vision" as fairly common: It can be hard to get workers to take a step back from the endgame results they're

Lean has been helping companies streamline their production, eliminate waste, and generally improve the way things are done for many years. Initially, the concepts behind lean were primarily used only in companies and facilities that were directly involved with physical product creation, such as manufacturing plants, factory floors and things of this nature. However, over time the lean methodologies have been adapted and implemented in almost every other type of business, ranging from health care to information technology, and many more. When done properly, lean can help improve virtually any work environment to help eliminate waste, improve communication, and to help ensure that the products or services being developed are indeed something customers will be interested in. For instance, when working in an information technology environment, it is important to be able to understand how lean strategies can be implemented, and why they are so important. The following are some of the most significant reasons why lean IT strategies should be taken seriously by any company that uses technology in their business (which is almost all of them!). Lean Promotes Ownership One of the things about lean strategies in an IT environment is that virtually every task completed is owned by an individual. Even if a person does not do all the work for a particular project, he or she will be directly responsible for overseeing it. This creates a sense of ownership, which can help in a variety of ways. It will give other teams a single point of contact for obtaining updates, providing feedback, or requesting changes. This will also allow the owner of a specific project to drive the progress directly, rather than having to rely on large committees or other types of groups to receive pertinent information. It is important to note that just because one person owns a process or project does not mean that he or she can simply dictate things to other groups. Instead, that person is there to

A swimming pool is a very good addition to any home as they add luxury and a place to cool off during hot sunny days. You should note, however, that swimming pools are just as dangerous as they are fun if the proper safety supplies are not implemented during use. One can easily drown in a swimming pool if you are not careful enough to follow good guidelines such as not swimming alone, and not diving headfirst into any pools that are not extremely deep and allow for diving. This holds especially true if you are not a good swimmer. You should therefore make sure to have safety products and supplies on hand at all times when using swimming pools. It is also wise to ensure that there is some form of supervision when the pool is being utilized. You can employ the services of a professional life guard or have a grown up look after children who are using the pool. You should note that the life guard should also implement the use of safety products and supplies irrespective of how good they are at swimming. Safety supplies for swimming pools start with exterior elements that ensure the pool is safe for use. You can start by putting up a fence and gate. Such steps to ensure the safety of small children who might wander into the vicinity of the pool is especially important. As well, safety supplies are very effective in restricting access into the swimming pool for others who might not appreciate the dangers. This will ensure that unauthorized persons who are not well experienced in swimming can not access the pool without authorization. You can also opt to put a cover over your pool. This will ensure that your pool is not contaminated by debris. It also prevents people from falling into the pool when it is not in use. Other safety supplies include floatation devices. Floatation devices can either be worn or used separately, such as when one holds onto the device and/or lays atop of the floatation device. Floatation devices come in very many shapes and sizes all dependin

These days you may be hearing a lot talk regarding "going lean" and "implementing lean practices," what does this truly mean? When a company implements lean practices they are essentially looking at all areas within the company, evaluating processes, searching for new ways to streamline and improve current processes, all while striving to create a better and more efficient product or service. Even though the implementation of lean practices is a significant undertaking it is well worth the effort with added benefits in production, efficiency, and cost savings.

Improving and Implementing Safety Lean Manufacturing Safety Lean ManufacturingWhen people look at facility improvement opportunities they often look at process improvement methodologies, such as Lean Manufacturing. Another thing that is commonly reviewed is facility safety improvements. In many cases, however, they don't see that using lean manufacturing techniques can often also provide safety improvements. Thinking about safety lean manufacturing will allow you to make improvements throughout your facility in a way that will not only reduce waste and increase profitability, but also help improve safety at the same time. The following are five examples of how lean can directly improve safety within your facility. According to DesignSafe's document on, Integrating Safety and Lean Manufacturing Safety must not be viewed as a separate activity that is a non value-added effort with objectives contrary to lean concepts. Elimination of waste can also be interpreted as the elimination or minimization of risk that adversely affects wasted human resources and lost time from injuries. Lean imperatives of faster, better, and cheaper must encompass the issue of running safer as well. Safety Lean Manufacturing - Top 5 ways to Combine Them 1. Eliminate Overproduction to Reduce Unnecessary Interaction with Machines Safety Lean Manufacturing OverproductionOne important focus for lean manufacturing is the elimination of over production. While this is mainly done to help eliminate waste, it will also make for a safer facility because people won't be working on the machines as much. Any interaction with the machine is an opportunity for an accident, so this is a good move for safety too. Look also at the fact that when people are spending more hours working at a machine, they are likely to be more fatigued, which increases the risk for accidents and injuries. 2. Listening to Employees Improvement Ideas One of the trademarks of a good lean manufacturing program is t

Key considerations before implementing DevOps in your organization

One of the most common misconceptions out there is the belief that technology equates innovation. Innovation is the creation of new value through a better solution for a problem that either does a better job in solving the problem or does so in a manner that the solution is accessible in a larger set of circumstances by a larger number of people. On the other hand, technology is simply the tooling that holds the promise of new solutions but by itself, is meaningless. Enterprises can become enamored by the promise and hype about technology and go down long, complex journeys, invest millions in upgrading technology and still come out empty on the other side because they built technology for technology's sake. Even in well intention boards and C-suite, industry peer pressure and hype around technologies can force action that ultimately leads to massive investments in people, software, technology, and vendors but does not yield the ROI promised by the technology. Leadership The problem can be accentuated when not enough due diligence is done on the applicability of the technology to the enterprise given the current state i.e. the point in time when the technology is being introduced, the customer's propensity to accept the technology-driven solution i.e. are the users ready to embrace, adopt, learn and utilize new solutions and burning problems that necessitate the adoption of new technology to better solve the problem. When the timing of new technology introduction is gotten wrong, it almost always fails to deliver on its promised ROI. Leaders need to rise above the hype and peer pressure and ensure that they understand, first and foremost, the burning problems that plague their customers or make the bedrock of their future strategy. Next, leaders need to ensure and validate that the technology in mind can actually be used to solve the problem through rapid prototyping and minimal investment. Once customer feedback on the prototype has been validated, then only

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

On the A Lean Journey blog, Tim McMahon offered up the reins to Lean Six Sigma writer, Kathryn Thompson, about a case study in lean manufacturing and six sigma. Inappropriately titled "The Successes of Lean Manufacturing and Six Sigma: A Case Study," Thompson's post is sparse on details and any data backing up the claim that Midlake Products is a decent model for lean and six sigma. No disrespect intended toward Ms. Thomson, but this article is NOT a case study. It reads more like a press release for Midlake Products. Thompson's post gives a summary of this company's lean six sigma background and links to their website which, for all intents and purposes, is devoid of any significant examples of how they implemented lean or six sigma and what the pros/cons included. A case study is something that gives a reader some indication of a need for improvements, the processes implemented, and results. They are important documents for anyone who is contemplating starting a program and looking for basic firsthand perspectives from professionals in their industry or comparable production models. If one were to desire a real case study on the matter, I'd recommend this one from Lean Enterprise Institute for starters. It lays out the information in a more traditional way.

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

The safety of employee's remains one of the top priorities of many businesses. Without clearly defined safety guidelines, the health and wellbeing of employees is at risk. In order to ensure that employers provide the protection necessary, OSHA provides the guidelines needed to develop a safety plan. Many states have enacted their own rules for safety plans; in fact at least 24 states have enacted their own state mandated safety plans. Furthermore, many businesses choose to turn their safety plans into one detailed safety manual that can be utilized by employees in nearly any work position. Reasons for an OSHA Safety Plan OSHA safety plans are written documents that outline the processes and procedures to help avoid health hazards and injuries, as well as identify the proper steps that should be taken if an accident does occur. This is especially important when it comes to hazardous work environments such as construction sites, factories, mining caves, and long shoring. For example, when a new construction project is being started, an OSHA safety plan will be implemented. First, the employer will need to thoroughly assess the project site for potential health hazards. Each hazard should be accounted for. Once the hazards have been identified, remedies should be sought or provided to either lessen or remove the hazard completely. When looking to reduce a hazard, steps such as providing personal protective equipment or using a special type of safety scaffolding for employees working at heights of more than 6 feet should be implemented.

Back pain and injuries account for some of the most reported and most serious common workplace injuries worldwide. In fact, you'd be hard-pressed to find a country whose labor department doesn't dedicate pages of literature to both employers and employees solely on this topic. Loss of work days and productivity, lifelong injuries and disabilities, and short term discomfort are all common results of lower back-related incidents. According to an OSHA fact sheet, More than one million workers suffer back injuries each year, and back injuries account for one of every five workplace injuries or illnesses. Further, one-fourth of all compensation indemnity claims involve back injuries, costing industry billions of dollars on top of the pain and suffering borne by employees. okstate.edu - OSHA Fact Sheet While employers have a responsibility to their workers to implement training programs that minimize injuries (and proactively improve the ergonomics of work-related tasks), employees also need to respect their own bodies and know their limits. This article will be broken up into several sections, each relating to specific aspect of lower back injuries in the workplace, with a primary focus on prevention. Anyone reading through should have a solid grasp on this all-too-common workplace plague by the end of their brief time here. Let's begin. Eliminate Back Injuries While we'll get to proper lifting technique and some employee-level suggestions in a minute, one of the best things employers can do is actually seek to eliminate lower back hazards from their workplace altogether; this is known as elimination - getting rid of risks period - and should be your first step in improving safety before moving on to prevention - mitigating risks that you and your workers have to live with in order for your business to function. Most lower back injuries are associated with lifting, and the most dangerous zones for humans are when lifted objects are below the knees or

We all know how irritating it can be to lose something we need. Whether we lose something simple such as a pair of nail clippers or misplace the correct size wrench to fix an immediate automobile problem, when something becomes lost or misplaced it results in a loss of productivity. Instead of using the item to meet its intended purpose, we are scrambling around searching for the item causing a loss in valuable time that could be spent doing other, potentially more important activities. The U.S. Marine Corps understands the value of lost production time and has implemented a specific tool control program to help counteract the occurrence of lost tools(tool control program). How the Tool Control Program Works The U.S. Marine Corps utilize the help of many tools to service varying levels of Navy aircraft, in fact there are more than 100 different service maintenance requirements and each service procedure requires its own set of tools. The sheer amount of tools needed to service the differing Navy aircrafts is mind boggling. However, it order to keep tools organized and easily accessible when needed, a specific tool control program was enacted. The program basically involves the usage of customized tool boxes that contain specific tools. The intent is that each tool has a specific location within a certain toolbox, which allows for a quick inventory check to verify that all tools are present when a maintenance requirement is conducted. Then, once the tools have been used, they are placed back into the correct toolbox and into their exact location for the ease of future use. Most of the toolboxes utilize customized cut foam to safely and efficiently cradle the tools. The goal is to make sure all tools are properly put away when not in use and easily found when needed. Since implementing the tool control program, there has been a significant amount of savings in time, space, and money within the maintenance department of Navy aircraft.

A3 image via Reliableplant.com Today, I was looking for a decent A3 problem-solving template for an engineering friend who was planning on implementing a lean program for his company, and I came across a helpful article on ReliablePlant.com by Larry Rubrick and a cool A3 powerpoint presentation at PowerShow.com (don't hit download, just hit play). As many people may know, the A3 format originated around the type of paper (A3, 11″x17″ sheet) that the Toyota Production System engineers used to base their problem-solving templates - with the mindset that using only one piece of paper kept the thinking process focused and simple. The A3 is said to be one of the main building blocks of Lean thinking. On the report, a problem is identified and then it follows a process of successive stages (including objectives or goals) by which it may be solved, or at least lessened. I liked the examples Rubrick offers in his post, starting with the requisite Toyota A3, and moving on to others, including an A3 at Ford in the United States (which is meant for a typical copy paper size, 8.5 X11). Other A3s can end up getting more illustrative, but the gist of it is best represented in the simplicity of the TPS template, I think.