Within Lean there tend to be strive to remove stock to the point problems start emerging. However, there is also sometimes necessary to have a buffer stock between processes and also sometimes a delivery buffer.
Buffer:
Used to even out variations in customer demand or unevenness within the production process. Within Lean we strive to have as low buffers as we can so they don’t become muda (waste).
Today I have added a book to the book section that I highly recommend!
One of the greatest challenges when it comes to Lean is to adapt the thinking of the iterative continuous improvement was to problem solving. In my opinion this is aided by examples from the real world. It is important though not to see them as guides of how to do but rather ideas on how to approach a problem, how to think in the face of challenges.
Of all the books I have read so far this is one of my favourites. We get to come along with James P. Womack on his journey of going to the Gemba and seeing for himself. A valuable insight in to one of the more known students of Lean.
Chaku chaku is a way to set up a production line. It is japaneese and litteraly means “load load”. It is a semi-automatic set up in the spirit of autonomation. Automation with a human touch. It can applied successfully in many different situations and can be adapted to be used in many automated processes.
The basic idea is that you have a series of automated machines doing work on the product. The operator oversee the process and also load material into each machine used to assemble the product. Hence the name chaku chaku or load load. A single operator can this way oversee a number of machines and handle any disruptions while continuously supplying the line with materials.
The system is also scalable to counter shifts in demand on TAKT time. In a hight demand situation more operators can work together making every operator load fewer machines per operator or even down to one machine per operator. In a low demand situation an operator can load more machines thus lowering the tempo but better adapting the workload on each operator.
Sometimes the journey of learning any new skill is hard. But in my opinion it’s worth it. The hardships and challenges is part of the process and is what ultimately helps you attain new knowledge and wisdom. This is expressed very good in these two quotes.
“If this Lean stuff seems easy you’re probably not doing it.”
James P. Womack
“If you are not willing to learn, no one can help you. If you are determined to learn, no one can stop you.”
Zig Ziglar
When talking to people about work and improvements they often comment that they don’t know this or they don’t know that.
In the spirit of Kaizen it is important to remember that you improve yourself in increments just as you improve the process or the product. Strive to better yourself by challenging yourself and always try do to your best. Over time your knowledge and capacity will increase step by step.
Maya Angelou expressed this idea beautifully and as you know by now I am real sucker for good quotations.
“Do the best you can until you know better. Then when you know better, do better.”
Maya Angelou
