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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

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

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

Waste water treatment plants are usually operated by municipalities or private utility companies, and are regulated by the states wherein they reside, but their standards were enacted by the U.S. Environmental Protection Agency (EPA). According to the Safe Drinking Water Act of 1974 (amended in 1986 and 1996), all local treatment systems are regulated so that the water they treat is tested for contamination, their improvement plans are reviewed, they have onsite inspection to ensure that machinery and sanitation efforts are functioning properly, that personnel are properly trained, and that they comply with all standards (or face stiff penalties). On top of these regulations are safety expectations imposed by the Occupational Health and Safety Administration (OSHA) under the U.S. Department of Labor. Waste water treatment plants have so many potentially hazardous areas that can impact people, directly and indirectly. Who is Affected? Directly, employees at the plant run the risk of workplace injuries from working around the huge pumps, walking near and above open water treatment containment tanks, agitator pools, furnaces, pipes, and various other facility obstacles, machinery and equipment which can create pitfalls for unsuspecting workers. Indirectly, end users of the treated water run the risk of drinking and using improperly treated water, but this post is primarily concerned with the safety of workers and visitors to the treatment plant. Ways to Make It Safe Pump pipe marking label image from wikipedia Workers who must work near open vats of raw sewage or even treated water should have all opportunities for falling into the water prevented via various safety devices, warning signs, or precautions. Potentially hazardous holding tanks or agitators should have traction tape laid on walkways or catwalks to reduce slipping. All pipes should be clearly marked with pipe marking labels to display what the contents of the pipes are. Any electric panels should b

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

When most people think of LEAN, they think of manufacturing, and it is no surprise why. A recent post by Mark Bridges in the "Lean Six Sigma and Continuous Improvement Group" on LinkedIn, brings up the idea of using Lean strategies in an office environment. His post looked specifically at how the office side of a manufacturing company can benefit from Lean concepts. His ideas, however, can be applied to any office environment. Taking active steps to eliminate waste can save companies money whether it is eliminating excessive inventory made by a manufacturing line, or eliminating the need for excessive drive space on an email server due to unrestricted storage policies. Northcote Parkinson's Theorem One of the most interesting parts of his post discussed what is called the Northcote Parkinson's Theorem. This theorem states that, "…Over and above a certain size, an office style organization can generate enough work to busy itself with!" This is a simple way of saying that while office work may be necessary, it can easily become a bottomless pit of inefficiency. One can't help but recall the scene from the movie, "Office Space" where the manager drones on and on about the importance of "TPS Reports." This scene is so memorable to many people who work in office environments because it is so relatable. So, how can lean help to eliminate 'TPS Reports' and other forms of inefficiency in the office environment? The post and the comments people made agree that Lean manufacturing strategies can be used in office environments with minimal adjustment. This is a perfect example of waste in the office, and how Lean strategies can help to avoid them. Office environments print off reports, spreadsheets, emails, and any number of other things. Many employees have the idea that as long as they recycle the paper when done, it isn't wasteful. While recycling may be better for the environment, it really doesn't help the company's bottom line. In

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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

"Green Machine" (photo courtesyof Gulfcoastgreenenergy.com) I read a really neat article today on the Gulf Cost Green Energy website, titled "Going Green: The Practical Payoffs of Geothermal Energy," that reported about a guy in Texas named Loy Sneary who has a machine that can convert wasted energy from steam stacks, boilers, and oil wells. According to Mr. Sneary, we waste almost 60% of the energy we use to create heat or electricity. His machine is kind of like a fancy heat pump/steam generator, and just maximizes energy through heat induction between heated air or water and a refrigerant that converts to pressurized steam inside a coil that is then used to generate electricity-all without any emissions. Frankly, I'm not a scientist or even an alternative energy expert, but it sounds reasonably logical. They rigged it up at Texas A&M apparently, and it all just worked out peachy. I'm all for greener alternative forms of energy, and this certainly seems to take the cake for that. I will certainly follow this guy's development of this technology. My only concern is that this article doesn't have too much written up on it-maybe it's hokey, or maybe it's because it's being repressed. Or, it just hasn't had anything written up on it, yet. (conspiracy theories anybody?)

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

Large scale industrial units are devilishly hard to manage. There are hundreds of employees working under an establishment and the number of equipment, tools and machine components used are countless. If the tools and equipment are not categorized and stored systematically, then a lot of time is wasted in finding the appropriate tool or machine component before starting any job. To minimize this waste of time, the tools, equipment and different machine components are kept on different racks, which are categorized by rack labels. The labels distinguish the racks from each other and tell the employees what is stored in which rack. This article is going to discuss the need of getting the racks labeled, and the different types of rack labels available in the market. There are different types of rack labels available in the market such as the polyester warehouse label, multi level rack warehouse signs, magnetic warehouse labels, cold storage labels, cold storage rack placards, cover-up labels. These different varieties of labels are used for different types of storage units. Let us discuss in depth the different types of rack labels. The polyester warehouse labels are the toughest labels in terms of the physical abuse, shocks and harsh industrial conditions, they are withstood. These levels are better than the paper labels because they are tear resistant. There is a polyester film over the labels which protect the text from chemicals and abrasion. The adhesive used on the polyester labels help in creating strong bonds over any kind of surface. The labels are available in all kinds of custom sizes and shapes. The multi level rack warehouse signs are designed to get rid of the requirement to have long range scanners as they help in identifying multiple rack labels with one single label, which contains information about all the racks. The magnetic warehouse labels come handy when the labels are needed to be relocated over and over again. The labels are provided with mag

Safety managers know that everyone seems to have their own thoughts about workplace safety. In most cases, everyone seems to think that their opinion on the subject is a fact that everyone should follow. Whether it is the executive that thinks that workplace safety is largely a waste of money, or the front line employee who thinks that their experience means they don't need to wear the proper safety gear, it can be difficult to overcome people's ideas. David Castella, a marketing associate at ProcessMAP Corporation looks at all these myths in the industry in a blog post. In it, he asks for input about which ones but safety professionals the most, and which ones make their jobs most difficult. Common Workplace Safety Myths In the blog post, Mr. Castella touches on a number of myths that can lead to a loss of safety in the workplace. Some of the key myths he covered include: Workplace Safety Isn't Worth the Time - Many people in both management positions and front line employees think that safety is a waste of time. Helping to show them why this is a myth is one of the most difficult parts of a workplace safety manager's job. Slip & Falls Can't be Stopped - People often think of slip and fall accidents as events that can be reduced in frequency, but not eliminated. While it is certainly a hard task to eliminate them, that should always be the goal in every workplace. There is no such thing as a Perfectly Safe Workplace - This one is similar to the previous myth. When people state that it is impossible to have a perfectly safe workplace, it is essentially giving up. When you have a goal of perfection, you'll always be striving to make improvements. It is well worth your time to read through the blog post as he brings up a number of important points, and provides evidence to debunk these and other myths. When Mr. Castella posted this post to the Safety, Health, Environmental, Risk and Community Management group on LinkedIn, it generated some very in

The term HAZWOPER stands for Hazardous Waste Operations and Emergency Response Standard, and is a set of standards created by OSHA. These standards are specifically applicable to five groups of employers/employees according to OSHA, but they can also be used by many other facilities looking to improve their hazardous waste safety.

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Paper was invented by the Chinese and they were the first to have wallpaper by gluing rice paper to the wall, as far back as 200 B.C. By 104 A.D., they had progressed to making paper from rags and other textile waste. This was the beginning of paper that we have today.The history of wallpaper, from invention to the current day.

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

Workplaces today are extremely safe compared to what people had to endure generations ago. This is in large part because of the increased focus employers have put on workplace safety. Employers made this effort for a variety of reasons including regulatory pressure, the best interests of their employees, and of course, the fact that a safe workplace is a more profitable workplace. Despite all the great strides that have been made, many workplaces are still quite hazardous. The following 10 workplace safety mistakes illustrate just how far many industries still have to go. They can also help spur ideas for where improvements can be made in your facility. 1. Using Ladders Improperly One of the most common and most dangerous workplace safety mistakes is failing to use a ladder properly. People make many ladder-related mistakes in the workplace, all of which can be devastating. The following are just a few of the more common examples: Unsteady Ladders - If you don't take the time to properly steady the ladder when setting it up, it could easily slide out while you're on it, causing serious injuries. Leaning from Ladders - When working on a ladder, you should never reach off to the left or right as that can throw the center of balance off, which could cause the ladder to fall. Using Objects as a Ladder - Using scaffolding, chairs, stools, or other objects to reach high areas can be dangerous. These things aren't meant for climbing the same way a ladder is. Climbing too High on Ladders - One should never step onto the upper rungs of a ladder. Depending on how the ladder is placed, even several rungs down can be unstable. 2. Lack of Visual Communication The noise in many workplaces can be quite deafening at times, which can make it difficult to communicate. When it comes to safety, communication is essential. This is why it is so important to have visual communication options in any loud workplace. Visual communication can come in many forms including

Eliminating Awkward Postures For most companies, the work that employees perform on a daily basis can be quite physical. This type of physical labor can lead to a wide range of injuries. Of course, to improve on workplace safety it is important to do all you can to help reduce the amount and severity of these types of injuries. One easy place where you can start is with the different postures that employees take while performing their day to day activities. In many cases, they put themselves in awkward postures, which increase the risk of injuries to the back, neck and other parts of the body. Fortunately, there are typically alternative ways to do things or even tools that can do those tasks for them so they can avoid injury. According to OSHA: Working in awkward postures increases the exertion and muscle force an employee must apply to complete a task and compresses tendons, nerves and blood vessels. In general, the more extreme the postures the more force is needed to complete the task. Examples of awkward postures include performing overhead work, bending or twisting to lift an object, typing with bent wrists, and squatting. The important thing is helping to identify the awkward postures, and help find alternatives for the employees. The following five positions should be removed from the workplace as much as possible so that employees can complete their work with as little risk for injury as possible. 5 Awkward Postures that Should be Avoided 1. Working with Arms above the Head The first awkward posture that is commonly seen in workplaces is trying to complete tasks with your arms above the head. There are many examples of this, some of which could include holding up a board while it is secured in place, or even painting a ceiling. Any time you are working with your arms over your head, you are putting added strain on your back. In addition, your arms are going to fatigue much more quickly than they would in a more natural position. This can put you at r

How to Create Bumper Stickers for Your Sticker campaigns For everything from political campaigns to social causes and beyond, cars adorned with bumper stickers are a regular sight across the country. Regular stickers, even more common, are a staple of our world from a young age, and an easily recognizable object for even children. Have you ever wondered how they're made? Sure, there are many companies that print stickers and the like in bulk for a third party, but there are also countless custom sticker campaigns floating about with highly customized messaging, some of which sprang up nearly instantaneously from their creative parties. These aren't cheap, flimsy creations either, some of them are the backbones of grass roots organizations that have changed the way we think and live our lives. Whatever your idea or needs, you're reading this because you want to create your own stickers, labels, or some other similar creative piece with professionalism and reliability. Let's take a look at exactly how you might get that done. Step One - Get Your Printer Especially if you're going to be producing large quantities of whatever you're making, it will be important that you have a reliable printer that isn't going to break down on you. For this reason, I'd suggest a thermal printer. Thermal printers have relatively few moving parts compared to traditional printers. Thermal Printers 101: The primary way in which thermal printers differ from traditional inkjet type models is that they use heat to transfer or even produce text and images. There are two subtypes: thermal transfer and direct thermal. Thermal transfer printers heat an inked ribbon which is then rolled over a paper or high-graded vinyl, transferring an image. Direct thermal printers work with thermal-chromatic paper, but do not require any ink. A heating element is pressed against the paper in the pattern of the text or imagery desired, and the paper responds by changing color in those places.