Tag: #PPAP
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From Hours to Minutes: Applying SMED to Die Changeover Processes
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“The hardest part of SMED is not the stopwatch: it is the mindset.” Introduction Whenever guests come to our home, we can prepare dinner in two ways. In the first approach, a single person takes full responsibility and works throughout the day to get everything ready, including cleaning, shopping, and cooking. In the second approach,…
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SMED: Single Minute Exchange of Dies
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“Time is the enemy of quality and the friend of waste.” — Lean principle Introduction Back in 1950, the average time for changing tyres and refuelling was 67 seconds, something unthinkable in today’s F1 era. Now, they manage to service the car in just 3.2 seconds.” Twenty years later, that would be considered a slow…
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Waste is Not the Problem: How Mura and Muri Create Muda in Lean Manufacturing
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“A bad system will beat a good person every time.” – W. Edwards Deming Introduction In a supermarket, customer footfall is relatively low from Monday to Thursday. However, from Friday evening through Sunday, it increases significantly. As a result, staff are under-utilised on the first four days of the week and overworked on the remaining…
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Muda: One Bad Weld. Eight Losses. Zero Excuses
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“The most dangerous kind of waste is the waste we do not recognise” – Shigeo Shingo Introduction In the metro, on a train, or during a flight, everyone seems to be busy watching something on social media. On average, we spend 2 to 4 hours every day in front of a screen. While 20–30%…
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3G: Gemba, Genbutsu & Genjitsu – The Power of Going to the Source
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“Leaders don’t manage from conference rooms; they lead from the floor.” – Taiichi Ohno Introduction When Ram, Sita, and Lakshman were living in the forest during exile, Ravan kidnapped Sita. Lord Ram had two choices. The easy choice was to simply ask Lakshman to go and search for her. But instead, he chose a wiser…