Recently observing a company’s test lab. I was struck by how some of the problems were very basic, did not take a long time to identify, and had been going on for years. Imagine conducting tests on a chemical blend, and as you observed the technicians in action, you see them weaving in and out, bouncing from one table to another — busy but not efficient. Also imagine production personnel waiting anxiously for the test results — bad results would mean rescheduling production, retests and additional delays. Continue reading…

This is the second of a two-part blog on reducing inventory by uncovering savings opportunities in buying processes at a medical-device company. Continue reading…

Businesses often continue to struggle with high inventories – both finished goods and raw materials — after initial attempts at reduction. While they can make some improvement by using common sense, companies sometimes fail to apply the proper tools for attacking this form of waste, tying up millions of dollars that — if freed up — could fund acquisitions, equipment and technology upgrades, and other needs. Continue reading…

Jidoka is a Japanese word without a simple English translation. It has two primary meanings. One relates to autonomation, the practice of separating the operator from the machine for higher quality output and more productive work. The second relates to how managers respond to abnormalities and implement countermeasures. Continue reading…

I have consulted in many industries, and one question I am often asked is, “How do you think we are doing with our lean transformation?”
It’s an important question because many companies fall into the trap of conducting one kaizen event after another, where a lot of good work is accomplished, but there’s ultimately no measurable [...] Continue reading…

The medical device industry is facing a tough environment – US regulatory process, the device excise tax, sluggish sales, pricing pressures and caps on reimbursement rates. Many executives in this industry summarize the environment as “challenging” and “uncertain”. Another area of concern is the impact of globalization and outsourcing. Because of the tougher environment [...] Continue reading…