Our passion is in helping manufacturers excel operationally with the right demand-driven pull strategies regardless of industry. We stay abreast of the latest Lean and Six Sigma best practices and bring you practical applications of these right here in our white papers. If there are specific topics you would like to see covered, please drop us a note by clicking on the email us link above.
Inventory Optimization, Maturity Levels for High-Mix Environments
[White Paper] Written for manufacturing & distribution executives and supply chain managers, this whitepaper describes strategies companies can deploy to “right-size” their inventory in high-mix industries where SKU counts are in the 1000s. In this whitepaper we will summarize the purpose of inventory and look at the four maturity levels of inventory management, with the pros and cons of each method along with best practices and software solutions.
End-to-End Supply Chain Visibility, Maturity Levels & Best Practices
[White Paper] Today’s supply chain landscapes are being transformed as companies globalize and broaden their product mix in order to stay ahead of the competition. This whitepaper summarizes the four maturity levels we've encountered for end-to-end supply chain visibility as well as best practices & software solutions for meeting these challenges head-on with improved processes and controls. We hope this whitepaper will educate you on the “art of the possible”.
Optimizing Cycle Stock Lot Sizes and Rhythm Wheels
[White Paper] This white paper describes the challenges of setting appropriate lot sizes, the best practices companies can adopt to meet these challenges, and state-of-the-art analytical tools that optimize lot sizes and production cadences to balance the costs of changeovers with the cost of inventory in the face of an ever-increasing product mix. The whitepaper also describes strategies companies can deploy to achieve a faster, more flexible manufacturing “cadence”, which not only lowers manufacturing response times and cycle stock inventories, but it also reduces the errors in sales forecasts and thus safety stock inventories.
Variability in High-Mix Manufacturing Environments
[White Paper] When starting down the path of implementing demand driven replenishment, manufacturers are rightly concerned about the level of variability in their environments. The cost of variability manifests itself in higher inventories and longer lead times, and the presence of excessive variability complicates the deployment, management and sustenance of pull manufacturing systems. A natural question for a manufacturer to ask is: “How variable are my operations?” – the answer to this question will help to shape the strategies, structures, and management practices required to successfully support demand driven manufacturing.
Configuring SAP to be "Lean Friendly"
[White Paper] As one of the largest providers of Enterprise Resource Planning (ERP) software, SAP® is widespread in the manufacturing community. However, SAP’s features that relate to consumption-based pull replenishment, namely reorder point planning and part-specific kanban, are often not well known. Read more...
Lean Metrics: Is It Time To Replace Your Metrics?
[Whitepaper] Manufacturing executives continue to face pressure to improve performance. Many are facing eroding margins,shortened product life cycles, product proliferation, and are searching for ways to maintain a competitive advantage. Is it time to reevaluate your KPIs and ensure you're focused on the right metrics?
Top 10 Lean Myths, Misunderstandings, and Mistakes
[White Paper] It’s an undertaking many manufacturers are pursuing yet too few have attained: utilizing Lean to improve profitability, competitiveness,and operational excellence. One reason for the lack of success is due to several inaccuracies that exist around implementing Lean.Written for manufacturing executives and plant managers, this paper examines ten of the top myths,misunderstandings, and mistakes surrounding Lean, particularly in high-mix, complex manufacturing environments.
Redefining Operational Excellence for High-Mix Manufacturers
[White Paper] Manufacturers today are under tremendous pressure to increase profitability and demonstrate stakeholder return on investment (ROI). In order to meet these objectives and stay competitive in the global economy, executives are once again focusing on optimizing their manufacturing and supply chain networks. By redefining optimal manufacturing operations, manufacturers are meeting-- and exceeding--business objectives.
Supercharging ERP for Performance In Complex Environments
[White Paper] This paper describes the business drivers behind the escalating concerns about manufacturing performance and how performance optimization solutions can extend ERP to not only drive, but also sustain improvements in key performance indicators.
Lean Metrics: Motivating the Behaviors that Drive Performance Improvements
[White Paper] This paper describes how leading companies utilize lean metrics that motivate improvements in manufacturing performance. Specifically, it focused on how companies develop and deploy metrics that will increase throughput while decreasing operating expenses and assets such as inventory.
Five Flavors of Pull Manufacturing for Getting and Staying Lean
[White Paper] James Womack, Daniel Jones, and Daniel Roos used the Toyota Production System as a framework to popularize Lean Manufacturing with their bestselling book, "The Machine that Changed the World: The Story of Lean Production." Womack, Jones and Roos introduced the five principles of “Lean thinking”: specify value, identify value stream, make value flow, let customers pull and pursue perfection. It is the fourth of those principles that this paper addresses.
Adapting Lean: Modifying Traditional Techniques for Complex Environments
[White Paper] This paper describes how to improve manufacturing performance in a complex environment using lean manufacturing techniques. It concentrates on how complex environments are different from high volume environments, and therefore; require extensions to traditional lean manufacturing techniques via flow path management.