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Defining Lean Daily Management (LDM) Lean Daily Management (LDM) is a systematic strategy for building Lean habits and managing continuous improvement and daily operations in the workplace. It involves multiple aspects, such as Leader Standard Work and Lean management routines, visual management boards, daily accountability, and problem-solving where the work happens (Gemba). LDM improves efficiency, […]

What Is the 5S Methodology in Lean Manufacturing? 5S is a prevalent Lean manufacturing method in factories and plants that helps organize the workspace, optimize performance, and ensure a safer workplace. Its goal is simple: create a safe, orderly environment conducive to productivity at every workstation. In this article, we’ll delve into the setup of […]

Defining Shop Floor Management Shop Floor Management (SFM) is a leadership structure within Lean management aiming to streamline manufacturing operations on the shop floor, optimize daily management processes, and further cooperation between employees and management. SFM coordinates efficient production and ensures standardization, waste reduction, safety protocols, continuous improvement, and quality control. Evolution and Global Adoption […]

Managers bring plenty of technical knowledge to the table, but without structure in place, their talent risks being wasted. For example, they might put essential leadership activities on the back burner in favor of tackling issues on the production floor. Undoubtedly, mastering hard skills doesn’t necessarily translate into possessing soft skills. Not to mention that […]

A Gemba Walk is an operational control practice aiming to systematically validate standards, identify issues proactively, and generate improvement opportunities. A Gemba Walk structure ensures all management levels walk in the workplace. It involves going to the work area with a checklist, observing operations, engaging with employees, and asking questions. Using the right tool will […]

Table of Contents What Is a Gemba Walk Checklist? Used in Lean management, a Gemba Walk Checklist is a form containing a series of checkpoints and questions validated by managers during their regular Gemba Walk. Thanks to its structured approach, team leaders, managers, and directors go to the workplace (or Gemba in Japanese) to identify […]

Defining the PDCA and the Deming Cycles The PDCA cycle (Plan Do Check Act) is a methodology to develop and customize internal organizational procedures for quality, project, and problem management. The Deming cycle is the visual representation of that model. In other words, while the PDCA cycle is a systematic method for continuous process improvement, […]

Do your supervisors and managers need to be more accountable regarding your performance objectives? Do they have regular management routines (process audits, 5S audits, safety inspections, Gemba Walks, meetings)? Without Leader Standard Work and Lean Leadership Routines, you’re likely seeing skills gaps between your different team leaders. Address this challenge by implementing Leader Standard Work. […]

Maximizing performance is as complex as crucial in the industrial and manufacturing sectors. That’s why it’s essential to establish a continuous improvement culture. By anchoring this approach in the core of operations, achieving objectives and improving performance becomes a reality. What Is Continuous Improvement Culture or Kaizen? Continuous improvement culture, also known as Kaizen, is […]

Auditing processes in the manufacturing, distribution, and healthcare sectors is not merely a luxury; it’s the cornerstone of any organization striving for excellence in its products and services. Maintaining high-quality, safe, and efficient procedures cannot be overstated since the repercussions of subpar standards can be damaging, leading to lost customers, rework, product recalls, and reputational […]

What is a Safety Walk? What is a Health and Safety Checklist? Who Usually Conducts Safety Walks? Benefits of Implementing Safety Walks and Checklists Case Study : Health and Safety Inspections at TOMRA Canada Steps to Implement Safety Inspection Checklists in a Manufacturing Environment Workplace Safety Inspection Checklist (Example) Safety Checklist Questions for Manufacturers (Example) […]

In factories, daily production meetings and huddles are essential for maintaining a smooth workflow, keeping employees informed about progress, and addressing any issues that may arise. However, these meetings can quickly become ineffective if they are not structured properly. Here are some tips for running effective daily production meetings and factory team huddles: Segregate meetings […]

In today’s manufacturing industry, implementing a robust quality management system is essential for ensuring product quality, reducing defects, managing deviations from standards, and preventing the problem from occurring again. One such system is the Quick Response Quality Control (QRQC) system, a process designed to quickly identify and resolve quality issues. QRQC Origin The Quick Response […]

Leader Standard Work (LSW) unlocks operational excellence by defining and standardizing a manager’s daily, weekly, and monthly tasks. In turn, it eliminates process variation and establishes a framework for proactive leadership.  In this article, we’ll delve into the details of LSW, highlight the benefits, provide sample checklists, and suggest practical template ideas.  From manufacturing to healthcare facilities, […]

The manufacturing industry has a wide range of specific workforce challenges. Unfortunately, it can be difficult to find ways to deal with these issues, especially when your daily time and energy are limited. What are the primary workforce challenges in manufacturing, and how can you overcome them to ensure organizational health? Here you’ll find useful […]

In a manufacturing context with many growing industries, it is frequent for factories to add continuous work shifts in order to keep a production pace that answers the growing demand. However, while necessary, these additional work shifts add a level of complexity to the business’s operations workflow. More specifically, operations managers must deal with having […]

Frontline managers are essential to support daily operations. They coordinate shifts and work teams, ensure production planning, prioritize problem-solving and follow action plans with the support groups. Manufacturers that sustain excellent supervision practices get better control over daily operations. Thus, they improve synergy between operators, support groups and top management. Although some supervisors acquire good […]

The daily management of a factory and its operations is full of unexpected events and emergencies. To remain in complete control, each management level wants to anticipate and quickly solve the encountered issues. For some organizations, it can be hard to proactively identify problems, while supporting an internal improvement culture, before the problems negatively impact […]

What is a Gemba Walk? In the manufacturing industry, a Gemba Walk is the action of walking around a factory floor where operations take place in order to reduce Waste and improve processes. Managers perform this operational control to identify discordances with the standard and raise issues. A Gemba Walk is a proactive problem-solving practice […]

Gemba Walks enable supervisors and managers to detect, solve and transfer issues proactively. Otherwise, these problems impact performance indicators negatively and bring time-consuming activities in the manager’s daily work. One of the causes of a reactive system is managing in a firefighter mode. Why is Measurement Important? The main challenge is to conduct a standard […]

Which Type of Organization? Gemba Walks are a common practice on the production floor in the manufacturing industry. Performed regularly, Gemba Walks are an essential part of operational control and support a strong continuous improvement culture. Ultimately, Gemba Walks are useful for all organizations with the need to detect issues and generate improvement ideas proactively. […]

How to implement a systematic Gemba Walk Structure on the factory floor? Checklists, schedule, improvement meetings and more. (+ Free eBook)

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