Elegant Solution by Leandro Quinteiro
I remember it as if it were today, the day I graduated as a Mechanical Industrial Engineer in January 2003. I had a glimpse of what the future would hold for me, where I would end up as an engineer. Then I started to work in a multinational company and had as main responsibility the planning of machining machines, definition of rotation of cutting tools, creation of machining devices among other activities. So far, my workday was going very well, with the focus on my silo and getting better every day. My contact with Lean started when we bought a new machining machine and we did not have space to install it in the current process, I started to design several layouts in Autocad trying to make the machine fit with the least possible changes. Finally, after days of work, I found a solution that was perfect for me, I prepared the presentation for my board, I put two layout proposals and the costs of each installation. I was then ready for my presentation. Perhaps it was one of the worst professional experiences of my life, but it was certainly the most learned. We have a natural tendency to increase […]
How to make benchmarking a successful case?
Working in the automotive sector, where benchmarking is a common practice, I have noticed several behaviors of colleagues, sometimes enjoying as a moment of various insights, motivation, and transformation, sometimes sounding a little arrogant when they say that do not see anything good. Based on all kinds of feedback I have heard so far, I listed the most typical cases of stereotypes of visitors: One who is jealous and only points to defects. One who concludes that we are better and there is nothing to learn. One who has not learned anything because the type of business is different. The one who saw it, thought it was cool, but came home and did nothing. The one who saw it, thought it was cool, and did something. The one who saw it, thought it was cool, and made an incredible transformation. And this kind of person is rare! Why does it happen? Probably due to the lack of preparation to do the benchmark. In order to take the most out of a visit for benchmarking, I put together some tips, which will help to avoid mainly the first 4 stereotypes: 1. Preparation The visit should not be a “business tourism”. For […]
Lean implementation with purpose and results
Hi! I am Karina Oliveira, a Takt Lean co-founder. I would like to share with you a little about my philosophy of life, Lean. When people ask me why I have become a Lean Consultant and what is my purpose with that, I quickly reply, I want to change people’s lives through Lean. I want to see people happy and motivated because they are doing things that make their lives easier, make their work easier and less vulnerable to mistakes. I want them excited by contributing to the company’s results and motivated to learn and grow with the company. Throughout my career I have had the privilege to be part of the transformation of some people. From the first approach, the fear of the unknown, to the excitement of taking Lean concepts home and to life. It is important to highlight that it is a long journey, which we need to be resilient and diligent, but it is extremely rewarding. One step at a time, sometimes backwards, many others forward, but with the certainty that working by purpose is very worthwhile. When pursuing purpose, the leadership role is fundamental, however, I’d like to bring up a kind of recognition for […]
OPTIMIZE RESOURCES WITH FOCUSED MAINTENANCE
Many years ago, when I was working at the Maintenance department in a Multinational Company, I thought our Department was the best compared to similar ones. We believed that in the Main Assembly Line there was no production loss due to equipment unavailability and that brought a certain tranquility feeling for the Maintenance department. Everything was going well until the day we faced an unprecedented break in a machine and it took some days to be repaired. Thankfully, Production was not compromised by that. You might wonder, how did that not affect the Production line? How come? HOW DID THAT NOT CAUSE DISORDERS IN PRODUCTION? Despite of applying very good practices and having a strong Maintenance team, we realized that the deal factor in that event, when we didn’t have a single production unit loss, was not because our technical availability, but a large quantity of finished parts on stock. It became evident the need of reviewing our way of working. Along with it, the global organization made the decision to implement the WCM (World Class Manufacturing) and The Professional Maintenance Pillar was something that I started to work with. BASIC CONCEPTS OF FOCUSED MAINTENANCE: * The machine is composed […]
Lean Logistics: How do we implement it?
Marcio shares his personal experience in implementing Lean and makes a reflection by comparing Lean manufacturing to Lean Logistics. For some people, they picture the warehouse business with a simplistic view that a distribution center is just a place where boxes move around and reach the customer. It is a little bit more complicated than that, but we can summarize it by listing some characteristics: supplier capacity and quality, transportation, internal flows, product and packaging variation, dealer capacity, customer needs – good price, quality and part deliver as quick as possible. It is fair to say that when talking about Lean, the aftermarket piece of the automotive industry does not get the same attention that the manufacturing does. Considering the entire supply chain, the distribution centers were forgotten for many years and there still some cases, where this business does not get much attention. Focusing on the lean journey in Logistics, a question pops up: is it different to implement Lean thinking in a warehouse compared to a manufacturing site? The answer is no. There is no difference between these industry segments when the subject is to implementing Lean. The journey on warehouses go through the same roadblocks that any […]
Lean Leadership Prior to dive into details about lean leadership, I would like to make you think about some internationally famous leaders like Nelson Mandela, Walt Disney, Steve Jobs, Martin Luther King and so on …. Many others could be remembered here, but the key point here is, did they know the term lean leadership? Certainly not, because the term began to gain prominence in the past decade, however, they are definitely great lean leaders nonetheless! Each one of them with skills and power of massive mobilization and transformation, whether you like the cause or not. Leadership is leadership since the beginning, just a brief consultation to the best leadership manuals to realize that the essence is the same, influencing people, having courage, being a good communicator, making decisions, challenging the team and setting an example to be followed. So, for me what exists is a good leader and a bad leader. Some already are born with this ability and others need to seek their development. Obviously, we are experiencing a period of many uncertainties and the only certainty is that tomorrow will be different from today, as it has always been. Given this statement, the role of a leader […]
Pursuing Zero Defects
Pursuing Zero defects by using the WCM methodology. Sharing a personal experience from who led the Quality pillar. I am going to share with you a little piece of my journey in the Quality area and my experience working on WCM or World Class Manufacturing, which I had the opportunity to lead the Quality pillar. WCM is a program structured on 10 technical pillars and 10 management criteria which consists of achieving high levels of excellence. Its premise is to reach the “beautiful number zero”, such as Zero accidents, Zero defects, Zero breaks and Zero losses. Its creation is entirely due to Dr. Hajime Yamashina, professor emeritus at Kyoto University and member of RSA (Swedish Royal Academy of Engineering Sciences) The WCM methodology is based on the various pillars and it calls to the concept to pursue the zero number, although we fight battles that at first may seem economically unfeasible, along the journey we are able to understand that the main purpose of all of this is to create a culture of non-conformism and continuous improvement. The result of the application and development of the pillars converges to create people engagement, add value to the entire chain and to […]
Does your organization have the pre-requisites for a successfully Lean Journey?
Lean is to develop. The success on implementing Lean lies on developing the organization. You decide to implement Lean. You invest in training for some employees and leaders. The results will soon appear, correct? No, not really. Training people is fundamental, yes. But before investing in training, in methods and tools ask yourself: Does the organization have the necessary pre-requisites to succeed in the Lean day to day? But what pre-requisites are these? We can mention a few: Is there an environment of dialogue and trust in the organization? where problems are treated as a source of learning? Are people motivated to come up with ideas and suggest improvements? Is there recognition at all levels of the organization, from leaders to the floor? If your answer is yes, great! If you’re not so sure, how about starting there? Having a culture of improvement is fundamental to succeed in the Lean journey. But where to start? One way to initiate change in the organization’s culture is, for example, the old and well-known 5S program. Although, remember: we are not talking about 5S only on the shop floor! 5S in the office, too. At the boss’s desk? Yes! Change involves all levels […]
Have you been to the Gemba today?
Many of us have heard that going to Gemba is an essential practice for the success of Lean philosophy. But at moment with the social distance, you may be asking yourself, how do I go to Gemba? Gemba is a Japanese term that can be translated as “the real place”. Applying Gemba means going to the workplace to observe what really happens. The practice of Gemba is really important to better understand, what the main problems in the company are, collect data and information that can be used to improve the workplace, processes and organizational structures. It also serves as a basis to better understand your customer’s needs – what they seek as an excellent product or service. Until the first quarter of 2020, in many countries, we practiced Gemba by going to workplace, to the “front line”, to observe and understand how the work really happens, with the aim of observing and identifying improvements or solving problems. With the need to keep the social distance caused by the Covid-19 pandemic, many companies had to relocate their offices to their employees’ homes and redesigned factories and offices to meet health and safety standards. As an example, it was necessary to implement distance between people and processes, teams were distributed in […]
World has changed: Lean, now what?
Did you know that Lean philosophy can help us out of this crisis? Let’s reflect together! It was in the midst of market competitiveness, launch of products and services, unrestrained consumption, chaotic traffic, changes in the organizations and in the political-economic commands in Brazil and around the world, that an unique phenomenon called COVID-19 happened, and then everything stopped. This took us out of the comfort zone in an abrupt way and at first, we resisted, because the resistance phase is part of the process. However, the challenge proved to be relentless and the actions taken by the governments had directly impacted the modus operandi that we were used to. Everything changed at a glance! The way we do businesses and negotiations, way we work, study and how we acquire knowledge, our behavior, leisure and entertainment, among many other elements, no longer occur as we were used to. Suddenly, we can no longer travel, shop at physical stores, go to restaurants, and in many cases, employees were not even able to go to their workplace. Although, in order to protect itself from COVID-19 threat, society retreated to their homes and acquired new consumption habits and people immediately began to miss the good things of life, such as, a good food from the […]