Operational Excellence

Productivity conversations are always interesting conversations, generally they start about being more efficient in the organisation, when what is really meant is I want more out the factory, which is fine. We invariably talk about what has been done so far and how they lead the floor and the example they set themselves. One of my favourite little ...

It's not news that when you have a bottleneck in your process you have a problem, backlogs build up, sales don't go out on time, customers get frustrated and cash flow starts to suffer. Identifying your bottlenecks and understanding the value of them then is important, so why don't more people pay attention to them? Moreover why isn't more tim...

I don't know how many times I have the conversation or overhear the conversation about wanting to improve throughput in a operation by doing things quicker. Typically it's something like "Lets find that 1 or 2% additional speed and it'll be fine", I cringe every time and here's why, speeding up your operations will not give you the big bang ch...

How often have you heard or said something like "We are running behind again!" or "We are not meeting our output Targets", "The System says it should only take", "We have timed it and know how long it takes!". I've heard them quite a few times over the years and after a few questions and a little digging I come to largely the same conclusion each t...

When it comes to describing the LEAN Wastes I like the DOWNTIME acronym, it gives the added hint that these aren't good things. Most people know and attack the popular ones in the group, the loud ones if you like, Defects - it's out there big, bold, brash and hard to ignore. Inventory, it's in your face, always demanding more valuable (and costly)&...

Daily work life can be busy, meetings, phone calls, paperwork, emails, more meetings. It just never stops. By lunchtime, your head hurts and your thinking I just need 5 minutes to get things in an orderly list, then I'll be on top of it. The reality is that the rest of your organisation is probably having the same issues and as a result ultimately ...

LEAN is one of those things that every organisation, large, small, manufacturing or service should do, for me it's just obvious. A great many people see LEAN as a waste reduction process, there to cut costs and nothing else, and unfortunately this is the thing that tends to stick, and in some cases be promoted as the value of LEAN but it's not what...

When I talk with organisations about forecasting most tell me it's not possible in their industry, their customers don't know what they need so how are they ever going to know? That usually just code for our sales guys like to take orders rather than build relationships and understand the customer needs. Or they tell me they do this proce...

Over the last 10 or 12 years the term "True North", sometimes referred to as "North Star" has gradually become more of a talking point in lean circles. Now it's is increasingly cropping up in conversations around NZ lean and continuous improvement circles as well. So what is "True North", how can you find it, communicate it and use it and should yo...

Often you will hear an organisation talk about being 'lean' they have lean processes, they have driven down the waste in their systems, they have 5s and Kanban's and management by walking around, everyone is clear on the goal and so many more great things happening, in their manufacturing area. Yet take 10 steps into their offices, their servi...