Your Supply Chain Deserves More Than Reports — It Needs Real-Time Intelligence Achieving Operational Excellence requires more than just efficiency; it demands a strategic approach to optimize processes, enhance customer satisfaction, and drive growth through an efficient Supply Chain. A well-designed Supply Chain Dashboard is a powerful tool that can help you achieve this by […]
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Japanese KMI ➡️ KPI ➡️ KAI in Practice In many OpEx programs, performance management quickly becomes a jungle of disconnected numbers. Japanese management philosophy offers a very simple and powerful cascade that solves this: KMI ➡️ KPI ➡️ KAI 🧭 KMI (Key Management Indicator): The “WHY” KMIs are the few strategic indicators owned by top […]
Putting Strategy into Action (Top-Down & Bottom-Up) A Hoshin Matrix (also known as a Hoshin X-Matrix) is a strategic planning tool used to link a company’s long-term vision and goals to annual objectives, KPIs, and Individual Objectives all on a single sheet. Shaped like an “X,” this matrix visually maps:🔸 Long-term strategic priorities (3–5 years)🔸 […]
At Toyota, having engineers or managers stand inside a circle drawn with chalk for a long time is one of the most famous learning practices of TPS. Because this method was often applied by Taiichi Ohno, it is known as the “Ohno Circle”. 🎯 Core Purpose:🟢 To see reality (Genchi Genbutsu)🟢 To understand processes from […]
Let’s set up a suggestion system; let’s have boxes on the wall, cute suggestion forms, and rewards… Let the suggestions pour in, let the money roll in! 📦 Box on the wall📃 Suggestion forms exist💶 Even rewards exist❌ No suggestions, no results ⚠️ IN REALITYSuggestions go unanswered. After a while, the employee stops writing suggestions […]
The Name of Chaos is Always a Planning Problem…Production Planning ➡️ Material Planning ➡️ Purchasing In TPS (Toyota Production System), chaos is not a lack of planning, but the loss or confusion of process ownership. When these three departments are not clearly separated, what emerges is: A systematic failure disguised as a planning problem. In […]
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Mar
Mar
We set up a board and hold stand-up meetings every morning. But in reality: 🔴 Behavior doesn’t change. 🔴 Decision-making speed doesn’t increase. 🔴 Problems aren’t voiced, or simply cannot be. Meaning, there is a ritual, but no system. In many companies, even the ritual is missing. Why is Asakai Important in Lean Manufacturing? 1️⃣ […]
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Nov
Nov
Lean projects without value stream-based organization fail to maintain the initial excitement. In this article I explain why and how to fix it. I have witnessed many projects related to lean transformation. You know the initial excitement; kaizen workshops are established, teams are motivated, measurements are made. The place is filled with energy for a […]
A Conversation with Art Byrne in Tokyo I met Art Byrne in Tokyo in October 2011. He had long since retired from Wiremold, but in his own words, he had not been “successful” in retirement and had joined a Boston-based investment capital firm called J. W. Childs Associates as a managing partner. This firm bought […]
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Dec
Dec
Having covered the history of assembly line management and line balancing in the last article, in this article we will discuss the 3 key principles of effective line management and continuous flow in a production and/or assembly line. These are; are gathered under 3 main headings. In assembly lines, typically, only line balancing is done […]
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