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2016 | Leanhill

Yearly Archives - 2016

8 ways not to waste resources.

8 ways not to waste resources. Are cost reductions, shortened production times and better quality aggregates possible without costly investments? The Japanese concept of Lean Manufacturing says it is! The most crucial thing is to solve problems at the source and to identify the different kinds of waste – factors that consume our time, people, energy, resources and money. The philosophy of Lean Manufacturing originated in Japan. It was established decades ago in response to Toyota’s company crisis after the Second [...]


Lean is about to test things.

Not enough storage space at an FMCG company – A case study of Lean Optimization in four acts. Act I ‘Why didn’t the BlackTlen 300 gel go to the customer?’ The plant manager was very upset at the morning meeting the next day. ‘Because the production line didn’t make it,’ said the planning manager. ‘Nonsense! How could we even make it, if the warehouse has stopped collecting finished parts from the production lines and we don’t have space to store them anyway? I [...]


Improve your processes instantly!

Is it possible to increase efficiency, safety and quality, reduce costs and shorten production time without months of planning, trials and testing, endless meetings and presentations? Could these changes be permanent? Do we need experts to implement them? The Japanese concept of Lean Manufacturing assumes that the most important thing is to solve problems at the source, using the intellectual potential of the employees. There’s no shortage of problems in our daily work. From morning to evening, employees and their [...]


Give me the sand faster!

We need to improve the performance of the entire production line. We have identified the performance of the grasper and gantry excavator as a bottleneck. Preliminary suggestions talk about the necessity of: purchasing a bigger gripping device (grasper), installing more powerful drives, to speed up extraction. Following the concept of genchi genbutsu, ‘Go and see for yourself’, after day-long measurement and observations from the operator’s cabin, the stages of the extraction process have been identified together with their time in seconds (minimally [...]


Free Competency Matrix – increase efficiency based on employees’ intentions.

Implementation of Lean at workstations usually starts with optimizing the overall workplace organization, maintenance of the tools and machines available to the workers, changing the way activities are performed, and joining positions. This delivers spectacular results. However, very often we skip the worker as a person, who also has professional desires and ambitions. Even the best set process handled by an unmotivated worker won’t provide optimum results. Is Adam Nawałka more familiar with tactics, techniques and physical preparation than Waldemar Fornalik [...]


„5 Whys?” – case study within mining industry.

The plant processing aggregates sought opportunities to reduce manufacturing costs. This was carried out for the following analysis. Stage 1 After analysis (P&L analysis, value stream map, process map, Pareto principle), the areas with the largest shares in the operating costs were identified: Stage 2 The first area that was subjected to observation was energy costs, identified in Stage 1 as the highest costs to the plant. The following chart presents the distribution of energy costs: Stage 3 In the subsequent stage, current levels of [...]