Tag: Lean

Act and audit

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watercolor painting of still life

George Taninecz MPI Group(Courtesy of Guest Blogger George Taninecz, VP of research, The MPI Group)

Did you make any plans for change in 2018?

Even this early in the year , many such goals and resolutions have already been abandoned. Or, at least, they’re at severe risk of being discarded. These failures are often not due to lack of desire. Most people who make resolutions do so earnestly, trying in some way to improve their lives, careers, personalities, or communities.

And yet why is it so tough to stick with our resolutions?

One reason is that we often embark on unguided resolutions. We lack the mechanisms to measure and monitor our progress toward our end goal. We strive for a marathon without running a mile. Even  the most ambitious resolution has a fighting chance if accompanied by a system to break it down into incremental actions and outcomes.

To achieve a year-end result (usually some form of a lag measure tallied at the close of the year), we need intermediary metronomes to keep us pacing toward the sought-after ending (lead measures). If we’re looking to lose weight, our weekly frequency of exercise and daily intake of calories will likely predict the 12-month outcome long before the new year rolls around.

For example, I’ve dabbled in watercolors for decades and have a drawer of unfinished (and unappealing) paintings to prove it. When I told my friend Jack, a distinguished painter, about my inability to finish a work, he matter-of-factly said that I need to practice finishing. So, with a resolution to improve as a watercolorist, my plan is to finish a painting twice a month. With each finished painting, I should move closer to reaching my resolution.

Some improvements and some resolutions may only require a “just do it” approach — you don’t need a future-state map to put out a fire — but most require time and long-term effort. Here, we can take a cue from lean practitioners.

When pursuing strategic goals, lean organizations establish routine monitoring throughout their operations to understand lead performances on an hourly, daily, weekly, monthly, and quarterly basis. With a regularly scheduled cascade of meetings up and down  the organization, teams share and review this information, take corrective actions if necessary, and escalate problems beyond their control up to the next tier of meetings. It is an endless whirl of many connected PDCA cycles (plan/do/check/adjust) that keep all aligned on the end goals. These companies may not always achieve their yearly targets, but they’re rarely surprised when they don’t. We, too, can regularly review progress, as well as engage others in helping us to achieve our goals.

We also can’t underestimate the need to actually do something: merely tracking our path toward progress won’t cut it. In order to accomplish a goal or in some way change our behaviors, we also have to act. This necessary cycle of actions, audits, and outcomes reminded me of a homily I heard decades ago: A parishioner prays weekly to God to win the lottery. After years of disappointment and winless, he lashes out and asks why God would refuse him. The voice comes: “You need to buy a lottery ticket.”

If we regularly buy a ticket — i.e., do the work to change — and have the means to periodically check the results, we at least have a chance to win with our resolutions.

How do I lower manufacturing costs?

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man working in manufacturing facility

(Courtesy of Guest Blogger Liz Fox, senior marketing associate, MAGNET: The Manufacturing Growth Advocacy Network)

As manufacturing shifts and grows through technological innovation and higher demand, shops are continually becoming more flexible and embracing the idea of slimming down. As a result, manufacturers are looking for ways to save money without sacrificing valuable manpower, processes, or components. If your efforts aren’t producing ideal profit margins, the following are some valuable cost-reduction ideas that should be considered in your long-term plans.

Assess and enhance your processes.

Before taking the next step toward cutting costs, you need to assess your manufacturing processes by looking at them from every angle. What details do you notice? Are there unnecessary steps or equipment? When you look at the big picture, it not only tells you where things can be improved, but gives you guidance on how to innovative so that materials aren’t wasted, labor isn’t costly, and scrap is minimal.

This can involve the following:

  • Implement additive techniques to reduce development time and use less expensive materials
  • Make better use of suppliers by evaluating and prioritizing your current needs
  • Modify designs to make them more cost-effective
  • Adopt Lean manufacturing and create a culture of continuous improvement

Go green.

Companies now are more receptive to sustainability as a key pillar of their day-to-day operations, and this means cutting back on energy consumption. With the right blend of technology, real-time data, and other resources, companies can run slower without disposing of good customer service or creating longer lead times. Take initiative by installing energy-efficient lighting fixtures, rescheduling the use of high-powered equipment, and putting together a special team to ensure all energy-oriented manufacturing costs are being managed appropriately.

Consider the cost of inventory.

Inventory space utilized for a long period of time can lead to high costs for storage, maintenance, and insurance. Take measures to make your operations more fluid, responsive, and oriented toward noted actual demand, which can help you avoid overproduction, cut the amount of waste, and substantially reduce cash spent on space for additional product inventory.

For more information, contact MAGNET at 216.391.7002 or visit manufacturingsuccess.org.