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By Xavier Perrin (xperrin@xp-consulting.fr) “Go See, Ask Why, Show Respect”. The words of former Toyota Chairman Fujio Cho, as reported by John Shook in one of his insightful letters on the Lean Enterprise Institute website, sum up very well the principle of “going to the gemba”. Gemba means “the real…

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Par Olivier Carré, O2C (olivier.carre@o2c-sc.com) My colleague, Olivier Carré, presents here different approaches for developing a master schedule in low-medium volume production environments. – XP Production planning for short or medium production runs is highly difficult today. Just as it is simple to schedule recurring products, it is just as…

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By Xavier Perrin (xperrin@xp-consulting.fr) The sanitary and economic crisis we are living for several months have tremendous effects on supply chains worldwide: disruptions in supply, insolvencies, stockouts of strategic supplies (protective masks, respirators, hydroalcoholic gel, etc.). Entire sectors of economy are jeopardized and will probably never recover the conditions prior…

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By Xavier Perrin (xperrin@xp-consulting.fr) When I am working with High-Mix / Low-Volume (HM/LV) manufacturing companies for helping them to improve their dependability, reduce their lead times, and reduce their working capital need, a frequent misunderstanding comes from executives about pulling production from customer demand. As they produce only what their…

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By Xavier Perrin (xperrin@xp-consulting.fr) I often read posts on professional social networks which recall us that “Client is King” or “Client is the Boss”. Most of the comments describe situations where it was missed to serve the client as a king, which is considered as a scandal. I’m always very…

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By Xavier Perrin (xperrin@xp-consulting.fr) Many articles, mostly related to lean principles, insist on “respecting people” as a necessary behavior of managers and leaders. This is often highlighted by quoting Toyota’s leaders, like former president Fujio Cho and is famous slogan “Go see, ask why, show respect”. Showing respect sounds obvious…

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By Xavier Perrin (xperrin@xp-consulting.fr) Different mnemonics are used to help people remembering the 8 muda. Recently, I discovered a video using the acronym DOWN TIME for Defects, Overproduction, Waiting, Not utilizing talent, Transportation, Inventory excess, Motion, and Excess processing. TIMWOOD is another tip for recalling the 7 wastes of Toyota: …

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By Xavier Perrin (xperrin@xp-consulting.fr) In a recent issue of the newsletter of the French Supply Chain Magazine (#2600 ; 20/11/2017), I found an interesting topic for illustrating the principle of muri. Muda is a well-known concept of lean, which is translated by “non-value-added activity”. Lean thinkers also learn to identify…

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We are teaching that “forecasts are always wrong”… and this is true! But, some people take the opportunity of this truth to assert that forecasting demand is useless…

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By Xavier Perrin (xperrin@xp-consulting.fr) For some time, articles and posts about Lean 4.0 are spreading over magazines, blogs and social networks. This idea –  Lean 4.0 – is related to the concept of Industry 4.0, whose promoters explain that the emergence of new advanced technologies like 3D printing, robots, big…

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