Stuck with continuous improvement?

This post is a kind of post scriptum to “Improving  50% is easy, improving 5% is difficult” in which I described 3 stages of improvement and ended stuck with continuous improvement as the Return On Investment (ROI) in C stage was not worth going on. Now assume it is not possible to radically change the … Continue reading Stuck with continuous improvement?

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Theory of Constraints, Lean and aviation MRO

In a previous post, “CCPM helps shorten aircrafts MRO”, I explained the benefits of Critical Chain Project Management (CCPM) for reducing the aircraft downtime during their mandatory and scheduled MRO. If CCPM is great and helps a lot meeting the challenge, it will not squeeze out every potential improvement, thus time reduction, on its own. … Continue reading Theory of Constraints, Lean and aviation MRO

CCPM helps shorten aircraft MRO

Facts Aircrafts have to undergo periodic Maintenance, Repair and Overhaul (MRO). This is mandatory in order to insure the aircraft's airworthiness and overall safety. During these inspections and repairs, the aircrafts are grounded. For the owners and operators, the shorter the turnaround time*, the better. An aircraft is a huge investment and the ROI is … Continue reading CCPM helps shorten aircraft MRO

Improving  50% is easy, improving 5% is difficult

It is with this enigmatic sentence that one of my Japanese mentors introduced the growing difficulty with continuous improvement. What it means is that at the beginning of an improvement program or when starting in a new area, the first and usually the easiest actions bring big improvement, hence the “easy” 50%. This is also … Continue reading Improving  50% is easy, improving 5% is difficult

Why SMED is quick win in pharma – Episode III

Improving changeovers in pharma industry is a relatively quick and easy way to... quick wins, faster and easier than usually assumed. This series tells you why. Episode III: How to and Why it works In the previous Episode I explained the background of the lag of many traditional pharma makers in regards to Industry Best … Continue reading Why SMED is quick win in pharma – Episode III

Leader Standard Work

The very first time I heard about “leader standard work” and “scripted day” I was puzzled. Production manager myself at that time, in my view management must be ready for fixing things and react to all the random events that rain down onto a factory shopfloor. How could a day made of fixing unexpected problems be … Continue reading Leader Standard Work

What is a spaghetti diagram?

A spaghetti diagram, spaghetti plot or spaghetti chart is the drawing depicting the physical flow or route of: a part, raw material in a workshop or factory a human worker in his/her work environment a patient in his/her journey in a hospital nurses in their station a file or paperwork being handed over across offices … Continue reading What is a spaghetti diagram?

The 2 for 1 rule to reduce WIP and Lead Time

Organizations with high level of Work In Progress also have long Lead Time, according to Little's law. High level of WIP clutter the process and tie cash into the process, while long Lead Times do not help agility nor On Time Deliveries. In order to improve the situation it is necessary to drain the system of … Continue reading The 2 for 1 rule to reduce WIP and Lead Time

Why SMED is quick win in pharma – Episode II

Improving changeovers in pharma industry is a relatively quick and easy way to quick wins, faster and easier than usually assumed. This series tells you why. Episode II: What Gain? Why? In the previous Episode I explained the background of the lag of many traditional pharma makers in regards to Industry Best Practices (mainly Lean) … Continue reading Why SMED is quick win in pharma – Episode II

Why SMED is quick win in pharma – Episode I

Improving changeovers in pharma industry is a relatively quick and easy way to quick wins, faster and easier than usually assumed. This series tells you why. Episode I depicts the pharma background, introducing why mastering quick changeover is both mandatory and a hidden or long disregarded improvement potential Episode II explains what gain can be … Continue reading Why SMED is quick win in pharma – Episode I