Blog
Insights on production scheduling, lean manufacturing, and manufacturing software from 35+ years of industry experience.
Continuous Flow Manufacturing: Eliminating Batch-and-Queue Production
Implement continuous flow manufacturing to eliminate WIP, reduce lead times, and improve quality. Covers cell design, one-piece flow, and FIFO lanes for job shops.
Just-in-Time (JIT) Manufacturing: Principles, Benefits, and Implementation
Implement just-in-time manufacturing to eliminate inventory waste, reduce lead times, and improve cash flow. Covers JIT principles, prerequisites, and real-world examples.
Kaizen Events: How to Plan and Run Rapid Improvement Projects
Plan and execute Kaizen events that deliver measurable manufacturing improvements in 3-5 days. Includes team selection, scope templates, and follow-up systems.
Kanban System in Manufacturing: How Pull-Based Production Works
Implement a Kanban pull system in your manufacturing operation. Covers card calculations, board design, supermarket sizing, and integration with scheduling software.
Lean Manufacturing KPIs: The Metrics That Drive Continuous Improvement
Track the right lean manufacturing KPIs to measure waste reduction, flow improvement, and operational performance. Includes formulas, benchmarks, and dashboard design.
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.