Posts by Beneva Group

Henkaten is an approach by Toyota to deal with changes in their manufacturing system. It is one of the lesser-known words of the lean vocabulary. Often translated as “change point,” it is about managing a change. However, there is no magic behind yet another Japanese word. It is all just the basics like most methods…

Visual management is a hot topic in lean manufacturing. It is not a do-or-do-not method like kanban or SMED, but it is an underlying soft approach that just makes manufacturing easier. It won’t fundamentally change your operations, but it will smoothen a lot of problems. In this post I will go through the reasons WHY…

The goal is to have everything relevant easily visible on the shop floor. Ideally, this is through the design of the shop floor as part of visual management. But a lot of other information is hard to see directly and can be shown best through data. Every well-managed shop floor has their different dashboards and…

As mentioned in my last post, continuous improvement (kaizen) is done through people, ideally close to the shop floor. You should always look for people to develop and grow, as they in turn nurture your continuous improvement. While it is really hard to give specific recommendations that apply to everybody, let me muse a bit…

One core aspect of lean manufacturing is continuous improvement, or kaizen in Japanese. This concept emphasizes ongoing, incremental enhancements to processes, products, and services. Yet, there are commonly differences between how Toyota does kaizen and how the rest of the world does kaizen. These mostly relate to who does most of the kaizen activities. In…

Lean manufacturing is a great set of philosophies and tools to improve your production system, or for that matter any kind of operational system. Yet, many supposed lean implementations fail. One of the various reasons for failure of a lean project is a lack of attention to detail. Let me explain: Production Systems Are Highly…

Radu Demetrescoux has been a manufacturing consultant for 25 years and recently authored a Lean Toolbox (in French) with actionable details on 64 tools. He has seen the French manufacturing sector losing half its factories and is working to rebuild it. This is how he explains what happened and the way forward. It includes an…

To control any kind of system, you need to know its status. For a simple system like heating, the indoor temperature may be the key input. For something as complex as manufacturing, however, there could be a myriad of different measurements that can help you to control the system. In this context, KPIs (key performance…

In my last post, I started to look at factors that affect the efficiency of your line, in particular the percentage of value-added time by the operators. For this I have a good data set with fifty-three different observations. One major factor was the speed of the line. Faster lines are not only easier to…

Whenever I visit a factory where manual work is done, I try to estimate the percentage of value-adding time. This brings up an interesting question: What factors do affect the percentage of value-adding time? Let’s dig through my data to see what matters. The Question Whenever I visit a factory where manual work is done,…