Bryan Bauw’s Post

Lean Journey #1 While the concept of lean manufacturing has been extensively documented, its core essence often remains elusive. Despite the mountains of literature, many involved in modern mass production struggle to articulate its fundamental principles. So, what is lean truly about? Those with practical shop floor experience understand that lean is fundamentally about ...SPEED. At the heart of any business is the pursuit of profit. To achieve this, a company must generate revenue before incurring expenses. This means efficiently transforming raw materials into finished goods. In the realm of lean manufacturing, the shortest possible throughput time is the most profitable route. To achieve this the manufacturing setup in an organisation must be nimble. How does it achieve this? By shedding all the 'flab' accumulated due to lack of awareness about lean principles. So it becomes imperative to understand the lean principles to remain profitable. #leanmanufacturing

Let us engage in Lean principles. We all have an idea of what lean is, but what is truly lean??? Lean is to be effective in what you are doing. Lean is to think outside the box. Lean is too be compatible. For example, the E.E.E. (Everyone, Engages, Everyday). Some think that Lean was created by Toyota Motors in 1991. Eliminate waste, build quality, deliver on time, Optimize work. The list can go on but we get the picture. While others believe it was founded by Henry Ford during the 1900’s to out produce is competition. But let us give credit where credit is needed. Lean origins dates to 1896 by Vilfredo Pareto the 80/20 rule, which means. In order to boost your productivity, what 20% of your product is 80% of your sales? And improve those 20%. If you seek to improve your productivity, your O.T.D, reduce scrap and be compatible, leave a comment. Our goal in the manufacturing world, is to be compatible with little or no waste. Thank you for your time.    

Lean Is The Reason Why Lean Manufacturing Transformations Will Keep Failing I have been reading all the (fake) reasons that have been listed on sites like these https://lnkd.in/gTQ9g772 or https://lnkd.in/gHyRQYk5 or https://lnkd.in/gkNJpVG8 or https://lnkd.in/gq448RT8 or https://lnkd.in/gcTAFvpw. What has struck me is that it is never mentioned that Lean itself (and its promoters) could be the only reason. OMG, why would they? Shahrukh, you dum-dum! Think maan! You stoopid, maan! In the attached article (which is essentially a collection of my posts on LinkedIn on a similar topic, I have objectively stated each of the 10 reasons why Lean has no substance and its promoters, most of whom are not Industrial Engineers, simply do not know what powers a production system, regardless of whether it is the Toyota Production System or We-Machine-Nuts-Not-Balz, a small CNC machine shop run by a talking seal somewhere in Alaska. Kindly read the article with an open mind and feel free to reject one or all reasons that I have discussed. At least offer an objective rebuttal for rejecting any reason. AND ....... if you would like to contribute more reasons, please do not hesitate to state them in this thread. Thank you.

KAIZEN Made Easy https://lnkd.in/gjdY8F4c Looking to streamline your processes and supercharge productivity? Embrace the structured approach of #AutonomousMaintenance & #KAIZEN! Here’s a quick rundown to implement these principles effectively: 1️⃣ Theme: Set a clear, overarching goal for your improvement initiative. 2️⃣ Reasons: Identify the why behind your current challenges. 3️⃣ Targets: Define quantifiable targets. Aiming for improved OEE? Chart your trajectory. 4️⃣ Current Situation Analysis: Break down losses, pinpoint problems, root causes, and select the right action methods through data analysis. Now, roll up your sleeves for the fun part: 5️⃣ Problems: Gather your issues without holding back. 6️⃣ Action Plans: Devise strategic plans to tackle those problems head-on. 7️⃣ Progress: Keep a close eye on your progress with regular checks. Once you've nailed it: 8️⃣ Effects & Results: Celebrate and document your wins. 9️⃣ Standardization: Make the best practices a norm. 🔟 Future Plans: Always look ahead. Plan for continuous improvement. By taking these steps, you create a dynamic workflow that not only identifies and resolves issues but also standardizes success for future endeavors. Remember, the key to KAIZEN is continuous improvement; it’s about being a little better today than you were yesterday. Let's make excellence our standard! #BusinessExcellence #ContinuousImprovement #ProductivityHacks #LeanManagement #Kaizen #ProcessOptimization #OperationalExcellence #SixSigma #Leadership

Attention Manufacturing Owners: Lean Manufacturing works! If you are looking for a way to improve output with your current resources: ❌ you do not need to buy more machines ❌ you do not need to hire more people ✅ Engaging your team and improving flow in your facility will lead to greater throughput (and profit). I have found embracing Lean philosophies and implementing appropriate Lean tools to be one of the best methods to do this in manufacturing and construction. I chuckle (and sometimes cry) as I think of all the Lean Pundits that will tear down this post and every Lean initiative that does not look like Toyota yet. They are missing the point of Continuous Improvement: Whatever state you are at, the goal is to improve incrementally and steadily. It is ok to embrace your current reality, especially if your production team is stressed and output is way lower than it should be. In fact, that is when you need Lean the most! I wish Lean Gurus would stop tearing into every post about Lean and instead find ways to encourage and engage companies so more people can be more respected and productive in manufacturing and manufacturing companies can thrive by improving daily. I have seen and continue to see the benefits for those organization with support from top leadership and commitment to Lean concepts: ✅ engaged employees ✅ improved throughput ✅ less stress ✅ improved profits ✅ culture of sharing ideas ✅ daily improvements throughout the organizations ...and yet none of my clients yet look like ideal Toyota Lean (Toyota themselves would not even claim this is possible) 👉 Is Lean thus a failure, I contend it is not! 👉 What say you, and why? Let the comments roll...

Philosophy & Lean: More Alike Than You Think! 🧐✨ When we think of philosophy, we often picture deep discussions on ethics, time, and meaning. But did you know that philosophy isn't just for scholars? It’s also the foundation of Lean Manufacturing! 💡 Philosophy is about deep thinking—the 4 Rs: 🟢 Responsiveness 🟢 Reflection 🟢 Reason 🟢 Re-evaluation These tools help us think better, act more wisely, and, ultimately, improve the quality of our lives and work. 💭 Lean Philosophy applies the same rigor to manufacturing systems, processes, and people. It’s a study of the 14 principles of the Toyota Production System (TPS), seeking to uncover the most fundamental questions about value creation and waste elimination. So, what does Lean Philosophy involve? Asking the right questions: What is value? How can we create more of it? Clarity & precision: Lean requires clear, careful thinking to continuously improve. Long-term impact: Understanding Lean weaves us into the fabric of an organization, preparing it for a long and prosperous future. 🌱 Remember, the word “philosophy” comes from the Greek words philo (love) and sophia (wisdom). By applying this love for wisdom to Lean, we strive not only to improve processes but also to enhance the way we think and work. Questions to Ponder: Are you applying the 4 Rs—responsiveness, reflection, reason, and re-evaluation—to your work processes? How often are you challenging the “why” behind what you do? Are you moving toward true value creation? Ref: https://lnkd.in/gPsB2p5z Ref: https://lnkd.in/gemTbN8C #LeanPhilosophy #ContinuousImprovement #OperationalExcellence #Manufacturing #TPS #ToyotaProductionSystem #ValueCreation

Toyota's 4Ps refer to the four key principles of their management philosophy, outlined in Jeffrey K. Liker's book "The Toyota Way": * Philosophy: Emphasizes long-term thinking, focusing on continuous improvement (Kaizen) and building strong customer relationships. * Process: Prioritizes waste elimination and streamlined processes, utilizing tools like Just-In-Time (JIT) and Kanban. * People: Invests in employee development, empowers workers, and fosters a culture of teamwork and problem-solving. * Problem-solving: Encourages a systematic approach to problem identification and resolution, using tools like root cause analysis and PDCA (Plan-Do-Check-Act) cycles. These principles collectively contribute to Toyota's reputation for quality, efficiency, and innovation.

10 Truths About Lean Manufacturing: 1. Lean is About People, Not Just Processes. 2. Continuous Improvement is a Mindset, Not a Destination. 3. Value is Defined by the Customer. 4. Data-Driven Decision-Making is Essential. 5. Lean Transforms Beyond Manufacturing. 6. Waste Elimination is Fundamental. 7. Lean Requires a Holistic Approach. 8. Standardization Creates a Foundation for Improvement. 9. Visual Management is Powerful. 10. Lean Demands Leadership Commitment. Lean Manufacturing isn’t just about making things better; it’s about making things right. It challenges us to strip away the unnecessary, focus on what truly matters, and push the boundaries of what's possible. It's about passion, precision, and relentless innovation—creating a culture where everyone is empowered to think differently and deliver exceptional value. In the end, Lean is about excellence, not just in what we produce, but in how we think, work, and grow.

Lean Manufacturing is often misunderstood, and it's time to set the record straight. The misconception that Lean Manufacturing is simply about "a lot of 5S" is far from the truth. This system goes beyond incremental improvements; it's a comprehensive business strategy that needs to be embraced in its entirety to yield real results. From macro to micro levels, understanding Lean Manufacturing as a system is key to its successful implementation and impact on continuous improvement. #LeanManufacturing #ContinuousImprovement #BusinessStrategy If you truly want to see the benefits of a Lean system, you must understand that it is a chosen journey that requires a culture shift. You won't regret it.

Turnaround Management Series -video:13 Real-world marvels of Lean Manufacturing with our latest video, "Real Success Stories with Lean Manufacturing - Case Studies In the first story, witness the journey of Toyota, a small player post-World War II that became a global powerhouse. Learn how the Toyota Production System (TPS), a pioneer of Lean Manufacturing, revolutionized their processes, making them agile, efficient, and globally competitive. Dr. Meganathan provides insights into Toyota's success, emphasizing Lean as a culture of continuous improvement. Moving on, explore General Electric's (GE) Lean journey in the early 2000s. Despite being a conglomerate, GE faced challenges in manufacturing efficiency. Discover how Lean principles, including 'Kaizen' and 'Six Sigma,' transformed their aviation division, optimizing production times and maintaining high-quality standards. Dr. Meganathan emphasizes the adaptability of Lean principles across diverse sectors. Finally, venture into the service industry with Starbucks' Lean transformation. See how Lean principles improved customer experience and streamlined operations, not in manufacturing but in a coffeehouse setting. Dr. Meganathan highlights Starbucks' success as a testament to Lean's universality and its holistic approach to operational excellence. https://lnkd.in/eHizqqNR