Getting the Ideas from the team and building a solution – Nominal Group Technique (NGT)

The nominal group technique is used to generate ideas from team in Problem identification, solution generation and decision-making. It can be used for teams of any size but ideally limited between 5 to 9 members. This number is ideal to get diversity and easy to find consensus among the team. Nominal group technique is particularly useful when few of the team members are more vocal than others. Generally a facilitator Read More …

Pareto Principle – A tool to focus your efforts on the Vital Few

The Pareto Principle, named after the Italian economist Wilfred Pareto is also called famously as 80-20 rule. As far back in 1906 Pareto observed that 80% of the land in Italy is actually owned by just 20% of the people. Much later, Joseph M. Juran popularized this observation in his book titled “The Quality Control Handbook”, and called this as the law of Vital Few. He observed that you could massively improve Read More …

Single-Minute Exchange of Die (SMED)

Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura). The phrase “single minute” does not mean that all changeover and startups should Read More …

Prioritizing Generated ideas using Project Prioritization Matrix

Previously we have discussed various ideas which can be considered for a Continual Improvement Project. Once all the ideas are identified, you need to rank these ideas. A total value for each project is calculated and plotted against an ease of completion number to decide which projects have the most value for the effort expended. The tool used to complete this technique is called as project prioritization matrix Why Prioritization Read More …

What is Value Stream Mapping (VSM)

Value Stream Mapping (VSM) is a Lean tool, to visualize the various steps and their contribution to the overall process. Value When a product or service has been perceived or appraised to fulfill a need or desire–as defined by the customer–the product or service may be said to have value or worth. Components of value may include quality, utility, functionality, capacity, aesthetics, timeliness or availability, price, etc. Value Stream All the Read More …

What is Rapid Improvement Event (RIE)

Rapid Improvement Event (RIE) is a 4-5 day process utilizing a team based methodology to apply the lean tools for seeing waste and making immediate improvement. The focus in a Rapid Improvement event is to work on the set up time or the Changeover time. Set-up Time Work required to change over a machine or process from one item or operation to the next item or operation; can be divided into Read More …

Cellularization or Cellular Manufacturing

In lean Manufacturing, Cellurization or Cellular Manufacturing is used to great affect. These are the Quality control tools used for cycle time reduction and set up time reduction. Cellular Manufacturing An approach in which manufacturing work centers (cells) have the total capabilities needed to produce an item or group of similar items; contrasts to setting up work centers on the basis of similar equipment or capabilities, in which case items Read More …