Lean learning cycle

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Un altro aspetto da non sottovalutare è il contesto competitivo in cui opera il nuovo imprenditore è decisamente agguerrito e pieno di persone determinate ad emergere, la recessione economica ha modificato lo spirito imprenditoriale: prima chi faceva l’imprenditore lo faceva per scelta ora chi fa l’imprenditore lo fa per necessità. Molte idee possono essere innovative ma poche sono quelle sostenibili nel mercato di riferimento, sotto questo aspetto il neo imprenditore opera in un mercato globale nel quale molte altre persone possono aver avuto la sua stessa idea.
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Pull systems are a nice way to control production between processes that cannot be tied together in a continuous flow, but sometimes it is not piratical to keep and inventory of all possible part variations in a pull-system supermarket .  Examples include custom parts, parts that have a short shelf life, and costly parts that are used infrequently.  In some of these cases you can use a  FIFO (“first-in-first-out”) lane between two decoupled processes to substitute for a supermarket and maintain a flow between them.  Think of a FIFO lane like a chute that con hold only a certain amount of inventory, with the supplying process at the chute entrance and the customer process at the exit.  If the FIFO lane gets full, the supplying process  must stop producing until the customer has used up some of the inventory.

Caveat:   Blitzes are all too often un-targeted, .  done with little concern as to the overall impact on the total company.   The results of such un-focused blitzes typically have a significant local impact, microcosms of excellence , but little or no impact on overall company well being.   See “Solutions Looking for a Problem” below.

  • Blow-Through BOM’s (Bills of Material):   Many “assembled product” manufacturers need to maintain subassembly identity, and/or control configuration, for replacement parts.   In these circumstances, rather than have a flat bill of material, it is much more practical to continue to show all subassembly levels on the bill of material. A “Blow Through” level, allows the subassembly’s parts to be called out, for kitting or backflush purposes, on the next higher level assembly.   The MRP algorithm “blows through” .  treats the subassembly’s parts as if they were called out on the next higher-level assembly.
  • Boom-Bust Cycle:   Some Causes:   I just got off the phone with a steel finishing plant / distributor.   He said that their on-time delivery performance was terrible, and that their lead times had extended considerably.   When I mentioned some ways to fix this issue, his response was classic:   “The customers have learned to expect it”   “We can’t turn down orders.   We just promise what they want to hear, then beg forgiveness.” And what do the customers do in these situations?   You’ve go it!   They double order.   They order high “just in case”.   They ask for it early, knowing full well that it will be late.

    If we let the person who’s best at performing the “specify” function handle more of that work, then we may also need to coordinate handoffs between ourselves. Adding the specify-complete column communicates to the team that a work item which was previously in the specify state is now ready to be pulled by anyone who wants to move it to the execute state. Work that is still in the specify state is not eligible to be pulled yet. If the owner of a ticket in the specify state wants to hand it off, he can put it in the complete buffer. If he doesn’t want to hand it off, he can move it directly into the execute state as long as capacity is available. It might be that the execute state is full, and the only eligible work is to pull another ticket from the ready queue into specify.

    Lean learning cycle

    lean learning cycle

    If we let the person who’s best at performing the “specify” function handle more of that work, then we may also need to coordinate handoffs between ourselves. Adding the specify-complete column communicates to the team that a work item which was previously in the specify state is now ready to be pulled by anyone who wants to move it to the execute state. Work that is still in the specify state is not eligible to be pulled yet. If the owner of a ticket in the specify state wants to hand it off, he can put it in the complete buffer. If he doesn’t want to hand it off, he can move it directly into the execute state as long as capacity is available. It might be that the execute state is full, and the only eligible work is to pull another ticket from the ready queue into specify.

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