Category Archives: Lean Tools

Discussion of experiences, implementation and best practices of lean tools.

Save Your Sanity with PFEP

PFEP simply stands for Plan For Every Part. A simple material control concept from the past resurrected and touted as a new transformative process. PFEP simply stands for Plan For Every Part . Material Control professionals first thought after introduction … Continue reading

Posted in Lean Tools | Tagged , , , , , , , , | Leave a comment

Lean Tools 101 – Run Chart

During our lean journey we oftentimes become overwhelmed with the jargon, anecdotes and theories. In our rush to out “Toyota” one another some of the foundational tools are lost in the process or simply taught in passing. I’ve seen leaders … Continue reading

Posted in Lean Tools | Tagged , , , , , , , | Leave a comment

10 Tips to Sustain Gemba

As we all know Gemba is the Japanese for “Real Place”.  The purpose of Gemba walks is to take management directly to the area where “value” is created to understand a situation thoroughly. In a restaurant this might be the … Continue reading

Posted in Lean Tools | Tagged , , , , , , , , | Leave a comment

After The Kaikaku

The big Kaikaku event is finally over, the smoke has cleared and the dust has settled. The armies of building contractors along with their heavy equipment have vanished as swiftly as they appeared. Also absent are the great gurus and … Continue reading

Posted in Lean Tools | Tagged , , , , , , | Leave a comment

IQR – Powerful Inventory Reduction Tool

Have you discovered IQR! IQR stands for Inventory Quality Ratio.  This is a very powerful and effective tool for inventory valuation, reduction and review. This is how it works. Divide your inventory into four quality categories. Active– Items with future … Continue reading

Posted in Lean Tools | Tagged , , , , , | Leave a comment

Is a Kaikaku in your future?

Kaikaku is the latest continuous improvement initiative being practiced in the business world. Kaikaku means “Radical change.” The goal is to tear down walls both literally and figuratively.  Kaikaku events are generally used when kaizen events no longer provide the … Continue reading

Posted in Lean Tools | Tagged , , , , , , , | 1 Comment

Lean and the Sole Source Supplier

Sole sourcing is one of many important issues Material Planners struggle. The primary question is how do I mitigate risk and lower inventory when using a sole supplier? The short answer is you cannot. The lower the inventory in the … Continue reading

Posted in Lean Tools | Tagged , , , , | 2 Comments

Don’t 5s yourself out of profitable business!

One of the most important activities of a lean enterprise is 5’s. You know Sort, Straighten, Sweep, Standardize and Sustain. The main premise is that only the tools needed to perform your job should be readily available at work station … Continue reading

Posted in Lean Tools | Tagged , , , , , , , | Leave a comment