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When you start researching lean manufacturing for the first time you’ll be confronted with a myriad principles, concepts, processes and tools, each of which have to have their own acronyms of course.

Lean manufacturing best practices are not that complicated! They are based on 3 common sense principles:

  1. A laser focus on providing value to the customer
  2. Identifying and eliminating waste
  3. Establishing a process of continuous improvement

In order to become a successful lean manufacturer these principles need to be baked into the company culture. Critical to that success is empowering each member of the workforce from C suite on down to apply lean principles at any time anywhere in the organization. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

The short answer is a resounding yes! You can be a two-person job shop or a 5000 person aircraft manufacturer and lean manufacturing principles apply equally. Lean manufacturing is a philosophy of continuous improvement (kaizen) with the goal of providing extraordinary value to the customer through a process of eliminating waste, (activities that do not add value), from every aspect of the operation. True lean manufacturing principles empower every individual in the organization to continuously improve value generating activities and eliminate non-value generating activities. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

The primary goal of lean manufacturing is to eliminate waste, (anything that doesn’t add value from a customer perspective), and inventory falls within that scope. So essentially lean inventory management best practices are focused on reducing inventory levels to zero. A worthy goal indeed but impractical to say the least. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Efficient inventory control is critical to the profitability of any manufacturing enterprise. However with so many inventory control methods available, it can be overwhelming to sift through them all to determine the best fit for your company. In general, manufacturers want to find a system that optimizes inventory levels, minimizes waste and consistently meets production line demands. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

The ways in which manufacturers extract and apply business intelligence (BI) are in transition. Depending on a variety of factors, manufacturers are relying on everything from manually produced spreadsheets to inflexible legacy ERP systems all the way to “smart manufacturing” approaches utilizing IoT and even IIoT.

While the overall trend is toward more integrated and flexible systems that can process voluminous amounts of data, yielding analytics and metrics for improved decision-making, a majority of manufacturers still have yet to commit to the newer, “smarter” technologies. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

A few months ago, we published a blog entitled “The Future of Manufacturing – Are You Prepared?” in which we stated that “… today’s manufacturing companies must reconfigure to emphasize agility, flexibility and ‘smartness’ in order to remain competitive in a rapidly evolving marketplace.”

Indeed, the rapid-fire emergence of “smart manufacturing” is quickly reshaping the landscape and will soon be “de rigueur” for companies committed to leveraging real-time business intelligence to reduce costs, improve efficiencies and speed up time to market, just to name a few objectives. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

In a previous article, we shared some insights into the rapid ascendance of mobile devices as key components in today’s ERP solutions and some of the high-level benefits that manufacturers can reap from their use. Entitled “The Top 5 Reasons Your Business Needs a Mobile Solution,” we supported the widely accepted premise that mobile apps, when integrated into ERP solutions, improve efficiencies and help reduce costs. What we didn’t mention in that blog is how mobility increases ROI. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

In last week’s blog, we looked at quality assurance (QA) best practices for manufacturers. In that post, we touched on the fact that many use the terms quality assurance and quality control (QC) interchangeably, even though they represent different functions in the overall quality management process. As we noted then, a distinction between the two terms is that quality assurance is process-focused and quality control is product-focused. Another way to view the distinction is that QC is designed to discover flaws or defects in a product or process and QA investigates the root causes that led to those flaws and seeks to correct them. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Quality Management is a rigorous methodology employed by a manufacturing company to ensure that the quality of its products is consistent. Two essential components of quality management are Quality Assurance (QA) and Quality Control (QC), which are often used interchangeably, even though there are distinct differences between the two. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

In previous articles we introduced Bills of Materials (BOM) and Material Requirements Planning (MRP), two legs of the inventory planning tripod. The third is the Master Production Schedule (MPS). As the name implies the MPS decides what products are manufactured and when. The required raw materials are then identified by the finished goods BOM, the data from which is then integrated with current inventory data to create the MRP for raw materials procurement. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.