Blog
Insights on production scheduling, lean manufacturing, and manufacturing software from 35+ years of industry experience.
Lean Scheduling Techniques: How to Schedule Production the Lean Way
Apply lean scheduling techniques including heijunka, pull-based scheduling, and level loading to reduce WIP, shorten lead times, and improve on-time delivery.
Lean Manufacturing for Small Manufacturers: A Practical Guide
Implement lean manufacturing in your small or mid-size shop without consultants or big budgets. Prioritized roadmap, quick wins, and tools that fit 20-200 person operations.
OEE (Overall Equipment Effectiveness): Formula, Calculation, and Improvement
Master OEE calculation with the complete formula, worked examples, benchmarks, and strategies to improve availability, performance, and quality in manufacturing.
Poka-Yoke (Error Proofing): Preventing Defects at the Source
Implement poka-yoke error-proofing in manufacturing to prevent defects before they occur. Covers contact, fixed-value, and motion-step methods with real examples.
Six Sigma in Manufacturing: DMAIC, Tools, and Real-World Applications
Apply Six Sigma methodology in manufacturing using DMAIC, statistical tools, and process control. Learn the difference between Six Sigma and lean, plus when to combine them.
SMED (Single-Minute Exchange of Die): Quick Changeover Guide
Reduce manufacturing changeover times by 50-75% with SMED methodology. Step-by-step implementation with real examples, video analysis tips, and scheduling integration.
Standard Work in Manufacturing: Building the Foundation for Improvement
Create standard work documents that stabilize processes, reduce variation, and enable continuous improvement. Covers the three elements, templates, and implementation steps.
Total Productive Maintenance (TPM): The Complete Manufacturing Guide
Implement TPM to eliminate breakdowns, reduce unplanned downtime, and improve OEE. Covers the 8 TPM pillars, autonomous maintenance, and real-world results.
Value Stream Mapping: A Complete Guide for Manufacturers
Learn value stream mapping step by step. Draw current and future state maps, identify waste, calculate takt time, and improve material and information flow in your factory.
Gemba Walks: A Practical Guide for Production Managers
Learn how to conduct effective Gemba walks in manufacturing. Covers preparation, questioning techniques, follow-up systems, and common mistakes to avoid.
Lean Supply Chain Management: Principles & Implementation
Implement lean supply chain management to reduce waste, cut lead times, and improve supplier performance. Practical strategies for manufacturing operations.
Lean vs Agile Manufacturing: Which Approach Fits You?
Compare lean and agile manufacturing across cost, flexibility, lead time, and inventory. Learn when to use each approach and how to combine them effectively.