GARY KAPANOWSKI: LEAN Manufacturing through Compact Machining Cell

This article describes the true intention of Lean to establish a continuous improvement cycle.  This group started with over 1,700 parts to categorize for production and tooling then to capacity.  This led ot a reorganization of the shop floor based on the pull from the customer.  This led to a “process family code system” for […]

GARY KAPANOWSKI: Experts discuss their mission to spread a culture of continuous improvement

The experts know.  Both Professor Liker and James Franz state that the implementation of Lean in organizations over the past 30 year hasn’t replicated the productivity gains made by Toyota.  In a way, this is disturbing.  As described in the article, the Toyota Way is a coaching model with a teacher/student relationship.  The Lean approach […]

GARY KAPANOWSKI: Lean Huddles work

This advance manufacturing organization adopted a Lean Huddle strategy to organize their tooling opportunities.  They didn’t know it was a huddle, but was used to get everyone to talk about the problem.  The answer was within the organization and the employees.  Testing different ways of production produced answers that were able to be applied throughout […]

GARY KAPANOWSKI: Throughput in Three Steps

It’s all about throughput – these days…. As it should be!!  Throughput is the start and finish of every process flow.  How can we meet the takt time?  How can we maximize our throughput?  These questions are asked frequently.  This article does an excellent job in organizing your thoughts on this issue. The three principles […]

GARY KAPANOWSKI: To U-Shape or Not to U-Shape?

This article points to several great opportunities when implementing Lean principles and tools to solve a problem.  First, the author points to Lean as “having very small amounts of work-in-process (WIP) moving rapidly through the entire process to the customer” or known as flow.  To improve the flow, a U, O, D or C looking […]

GARY KAPANOWSKI: How family status affects women at work?

Raising the corporate ladder is difficult for anyone.  The latest research indicates being a woman with kids is not a favorable indicator for success.  The positive indicator of mentorship boosts the results for women.  The interesting fact from the article is that the supply of women with credible education backgrounds would point to a more […]

GARY KAPANOWSKI: Part Inspection Speeds Up due to Standardization

This is a good article to describe the strength of standardize work instructions.  This included 100% inspection for critical functional characteristics.   With improvements, the total cycle time was reduced by 35% and now implemented throughout the organization.  Also, since the standardized procedure is simple to implement, reduction in training costs allows for other improvements to […]

GARY KAPANOWSKI: Kaikaku – Manufacturing Re-Imagined

How do we know if we are utilizing best practices?  The answer is in identifying the current state.  Kaikaku or radical change identifies the issue of stagnation to create a new process or model.  Thus, we are going beyond the Toyota Production System (TPS) for incremental improvement.  This is the basis for Black Belt studies.  […]

GARY KAPANOWSKI: Lean production of an external heart defibrillator/cardiac monitor

This article focuses on the Lean approach to correctly identify the voice of the customer (VOC) and install process improvements to eliminate waste and become more profitable.  After correctly identifying the current state value stream map, the voice of the customer was identified along with other areas of problems.  A series of kaizen events were […]

GARY KAPANOWSKI: How family status affects women at work?

Raising the corporate ladder is difficult for anyone.  The latest research indicates being a woman with kids is not a favorable indicator for success.  The positive indicator of mentorship boosts the results for women.  The interesting fact from the article is that the supply of women with credible education backgrounds would point to a more […]