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Pull connections - The 3 strategies

A Pull process is a process in which a workstation starts to work on his next order only when there is a free slot on the output side. This means the trigger for producing anything on the workstation comes from the customer side, which can be internal as well as external. The customer pulls orders through the process instead of a traditional Push connection in which products are produced no matter what happens on the output side of the workstation.
Because inventories between workstations are managed in a pull system, which directly influences and maximizes the Lead Time, Pull always has a preference over Push.
Three different forms of Pull connections can be identified: a work cell with Continuous Flow, Sequential Pull and Replenishment Pull.

The Production Lay-out

In the Lean Philosophy, the ideal way of organizing a production line is described to be a One Piece Flow, in which products are moved through different workstations and worked on separately. Liker (2004) describes seven advantages of this type of production, which include increased quality, flexibility and productivity.
But, is One Piece Flow always a viable option? I believe, that just like with every Lean tool, one has to think about whether or not changing the lay-out would bring the organization to a higher level.
This article describes what could be the ideal Lay-out for different type of production processes.

How to create a Performance Management System

This video explains in 7,5 Minutes how a Performance Management system should work.

The cascading of KPI´s from strategic to operationallevel is also described in the article: The gate of Purpose - Hoshin Kanri.
The communicationscells of the Level 1, 2 and 3 meetings should be set up as discussed in the article: Communication cell in Practice

Value Stream Mapping (VSM)

Value stream mapping is a lean tool that can be used to map processes in detail, based on the both the flow of material as well as information. Data boxes make it possible to write important aspects of each process step, such as changeover times, cycle times and machine availability, which makes value stream mapping a great tool to use in (re)designing a value stream (Panneman, 2017). In traditional lean initiatives, a current state value stream map is drawn first (described here), after which a future state map can be designed which is described in the article: 8 Steps of Future State VSM.

Learning to See - M.Rother & J.Shook (summary)

Learning to See, written by Mike Rother and John Shook, is the book to read for Value Stream design. In every Lean implementation, it is important to understand the current process design and the way the design influences the flow of products through the factory. After understanding the current state of production a structured approach is needed to get to an improved, future state of the value stream. Traditionally in value stream design, a team thinks of random improvements to reduce inventories or increase throughput, which can result in a lot of kaizen events which hardly really improve the bottom line results.
This article will focus on the most important part of Learning to see: the seven steps structured approach for designing the Future state Value Stream Map.

SIPOC

The SIPOC is a visual rendering of Deming´s System Model (Scholtes, 1998), a Model that is used to visualize the complexity of a system, where the word system is defined as a combination of processes, methods and employees, who work together towards a common target. The goal of the SIPOC – and Systems Thinking- is to visualize the patterns in a system, by looking at it from a whole, instead of from different pieces like departments or specific processes (Senge, 1990).
The value the SIPOC ads compared to the Process map or a Value Stream Map is that not only tasks or production steps are visualizes, but also the communication complexity between different departments or functions.
The next step after building the SIPOC would be to reduce these complexities, which will lead to higher effectiveness and efficiency in all its processes (Morieux & Tollman, 2014). This is why the SIPOC can play an important role in improvement activities, like Kaizen events.

Leading Change - J. Kotter (summary)

When it comes to change management, John Kotter is the most cited author worldwide. In 1995, his book Leading Change became an international bestseller. In this book, Kotter describes 8 necessary steps for cultural change. 17 years later however, he changed his vision on organizational change from a organization where change is implemented top-down, towards an organization of voluntary bottom-up improvements.

In this article, both the original theory of 8 steps is explained, as well as a short summary in which Kotter explains his new view on organizational change.

Lean in a Non-Profit Organization

A motivating example of Lean principles, applied in the Non-Profit sector:

5x Why example: Jefferson Memorial

This video explains how the ´5x why´ is used to prevent further decay of the Jefferson Memorial.
The solution is absolutely impressive!

Getting Lean in 90 seconds

A short introduction video which explains four Lean Principles: Pull, One-Piece-Flow, Takt and Zero-defects:

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