Derek Korn’s Post

“We must gamify manufacturing to attract new talent,” was a phrase I heard last week. While indeed rare, I saw that done very successfully over 25 years ago. The term “gamify” refers to “making it fun.” But behind the term is the long-held lean manufacturing belief that the value-adders in the process must have the feedback as to whether or not they are “winning or losing” against the daily production goals –preferably real-time or at least by the hour. What is missing from this idea that I saw 25 years ago is the prize for winning. A metal stamper of auto parts had the radical idea of publishing the production schedule for each press for the entire week. The schedule was based on a realistic OEE. The press operator was then told that after they produced the scheduled –and salable parts, they could go home early and still get paid for 40 hours. Each press was managed by their respective operator like their own business: the operator had a vested interest to see that the parts were good and that the change-overs were done in a timely manner. They monitored the press strokes and pace of good part production to “win” by leaving early on Fridays. Gamifying manufacturing doesn’t NEED the bells and whistles of monitors and red-green bar charts (although it can help). What it needs are: stable rules, a clear measure, and the PRIZE –and preferably more than “atta boy.” #strategywithactions #gamifymanufacturing #leanmanufacturing #lean #shopfloormanagement #winningorlosing #processmonitoring 

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Why do we have conflicting priorities? Is it because we don't have sufficient manufacturing capacity to support all lines of products? Is it because we have not lowered the barriers at bottlenecks? How do we communicate between the customer and the supplier? Are we constantly switching production chasing the latest perceived problem? Have we not done SMED work on our manufacturing?

This application of 3D scanning is neat to me. In this case, contract #CNC machine shop JD Machine Corp. JD Machine Corp. used Kaiser Manufacturing's Shadow Foam concept which scans the location of tooling laid out to create a CAD file from which rigid foam tool storage inserts are milled for cabinets, cases and whatnot. Not only did this help with the "set in place" portion of #leanmanufacturing's #5S concept, but "standardize" as well. For example, standardizing on tooling layouts makes it easier for shopfloor employees to find what they need when asked to move to another perhaps unfamiliar machining cell. But this is just one application of the technology. Think of how many other industry or even personal storage needs something like this could satisfy...

Lean thinking challenges metal fabrication norms Is waiting the secret to faster production in job shops? In an interesting piece titled "The counterintuitive nature of job shop production", Tim Heston explores how lean manufacturing principles can be adapted for custom fabricators. He delves into the complexities of applying lean concepts like waste reduction to job shops, where some inventory is necessary to keep production moving. Heston highlights the balance between serving major accounts and maintaining overall throughput. The article introduces insights from Prasad Velaga of Optisol LLC, who suggests that delaying order release can dramatically shorten lead times. Heston also discusses the importance of optimizing cutting capacity and controlling work-in-process inventory to improve overall efficiency. #LeanManufacturing #MetalFabrication #ProductionEfficiency #JobShopOptimization #ContinuousImprovement How has your shop adapted lean principles to custom fabrication? Have you found success in counterintuitive approaches to improving efficiency?

Many Process/Project and Operations Leaders/Managers could learn from this experience..... Repurpose/Recycle both : Processes(equipment and Infrastucture....) Lessons and also existing best practice where possible.. Why reinvent??? In my experience evolution is always better than revolution!

Need to invoke POKA YOKE in your manufacturing operations, Let's walk through these six steps. #kaizen-made it easy

Are your factory floor skills aligned with the demands of Industry 4.0? What are 5 steps to better manage your shop floor? (SPOILER ALERT, 1 of them is to eliminate the Paper Trail, but who doesn't want to do this!!!) In the fast-paced manufacturing sector, maintaining competitive advantage requires more than just cutting-edge technology; it's essential that your workforce possesses the skills necessary for success. Learn how to minimize downtime, improve quality, and cultivate a culture of continuous improvement that drives your operations forward. https://ifs.link/d8hr0L #Manufacturing #SkillsManagement #Industry40 #DigitalTransformation #OperationalExcellence #WorkforceDevelopment #ConnectedWorker

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