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Hi to all our LearnLeanBlog.Com readers. After a long time of inactivitiy and changes to the blog, we are looking to provide you more resources on lean manufacturing and related topics. But we want to be more relevant and resourceful.

Let us know the areas you would like us to touch in our future blogs. Please leave your comment below.


Welcome to all new learnleanblog.com

Hello. Wish you a happy 2014. This is the first post to learnleanblog in more than 1 year. Meantime, learnleanblog design changed and many things happened behind the curtains.

You, our readers and subscribers are the greatest asset we have. We hope to share the important information about lean and related areas in this new year 2014. Stay tuned.


In honor of Steve Jobs

Today, I am not writing anything about lean manufacturing. But, today, I am writing about a true personality of our time. A person made things possible and showed the way for thousands. Steve Jobs one of the best entrepreneurs and a good man, will no longer to announce his legendary iPhone version 5. After creating ripple after ripple in the world, he is no longer with us.

I am posting below the video from his extraordinary speech at Stanford University in year 2005. Just listen. It motivated me when I need motivation. I a sure it will do the same to you. Good bye Mr. Steve Jobs.

Few Quotes..
“…If today is the last day of my life, will I do what I am about to do…”
“..No One Wants To Die. Even People who wants to go to heaven do not want to die to get there.. “

We are with you My Japanese Friends

My dear Japanese Friends;

It was horrific to see all the disaster created by the Earthquake and the Tsunami. I just want to let you know that, we are with you! Hope everything get back to normal ASAP.

Lean for Apparel Industry – Part 1

As promised, my friend has sent me the first article on lean for apparel industry. As I always say, he also starts from 5S. Please read the article. If you like the article, tell the world by clicking on the LIKE button below.

5S is foundation for Lean

 If a company wants be a world class organization that company should drives and achieve below characteristics.

      Zero Down time

      Zero Waste

      Zero Missed Opportunity

      Zero Bureaucracy

      Zero “Hidden” Problems

To approach to this stage the path or main way is 5s.

5s Define as The Philosophy that lays the Foundation to create a Disciplined Mind, Which leads to disciplined thoughts which leads to Disciplined Actions – Action which improves Productivity, Quality, Cost, Delivery, Safety, Moral & innovation.

Why we need 5s?

1. Get EVRY BODY’S Involvement at EVERY LEVEL

          – 5S is the activity that each person works on part

          – 5S is the activity that all members’ participation is possible

          – Participative Actions – Huge Results

2. Creates a Pleasant, Safe and work friendly environment

3. Builds a Visual Work Place with Standard Work 

4.Taking ownership of what the team members are doing

           My machine  ->        my area    ->    my dept    ->   my company

5. Develops Kaizen Minded People

6. Strengthens Team Work, develops Leadership of all levels, reduces internal conflicts

7. Reduces physical & psychological stress of all employees

8. Reduces the resistance to change

9. Reduces hierarchal mindset and bureaucracy at work place

10. Unmasks the hidden organization

But most of the companies failed in implementation of 5s because of below reasons.
  1. We implement 5S not “Practice” 5S

  2. 5S implemented as “Look @ US” campaigns

  3. It’s designed to impress visitors, buyers

  4. 5S is implemented to win competitions than real improvement, after winning the competition no clear path forward

  5. 5S campaign itself becomes the goal

  6. Lack of vision and missing link to the company vision & Hoshin

  7. Lack of Top Management support

  8. Misunderstanding of driving 5S through delegation than the Site Leader on the saddle

  9. Under estimating the power of 5S in team building

  10. Most of mistaken with Housekeeping, forgets housekeeping is just a partthe pilot process of the whole journey which gives real time feedback on the plant culture and kick off of 5S

  11. Depending on Audits to sustain, more on pointing out than problem solving – “Here let us help you to keep this straight”

To eliminate these failure factors first we have to identify where we stands on.

That we can recognize going through the below categories.

1.    Objective

2.    Thinking

3.    Action

4.    Responsibility

5.    Result
Based on these categories we can compare the where we stands really.


Traditional Thinking

New 5s thinking



Profit Pursuit



Sustain & kaizen



Counter Measure


Spot Worker

All The Members


ProductionService Support

Improve PSQDCM






  10 Principles for implementing 5S

  1. Never let the 5S process itself become the goal. Keep in mind your true goal is achieving business excellence.

  2. To keep your process from getting bogged down, first get rid of all excess work in progress. If you setup and maintain a cellular concept flow will be created.

  3. Consider excess inventory as a major unneeded item to target.

  4. Everyone needs to be responsible for picking up “waste” including top management – no observersno delegation – you do it first.

  5. Clerical & administrative departments should also be setup in U shaped cells to provide observable 5S example.

  6. No “no man’s land” within the premises.

  7. Continued commitment & support from the top management to follow PDCA.

  8. All employees must be trained – human knowledge appreciates.

  9. Set KPI’s & include 5S to performance evaluating criteria. Concrete headed people to be exposed, others rewarded – stress individual participation.

  10. Never Ever Walk by an Unsafe Act or Condition.

Challenge1 – Sort – “Seiri”

Objective:- Identify and collate unwanted items, activities and Thoughts(ATTRACT)

        Question:- What “SORT” of actions we need?


      Red Tagging – every red tag has a why? Why? Analysis

      Quarantine Area for Red Tagged items

      Form Team Based Work Groups

      Financially cumulating the value of the items in Red tag area

      Disposal Policy & Scrap sales

      Lay the foundation for PROCESS MAPPING to get rid of unwanted activities

      ECRS ( eliminate, combine, rearrange, Separate)

      Identify Losses & DT’s

      Pick and Choose Supportive Tools

      Identify “Loss Based” Skill Will Matrix – ETHOS Pillar

      Training Plan on the philosophy

      Untapped human Potential

Why do unnecessary items accumulate?

  1. Sudden changes in the sales, production plan

  2. Excessive ordering

  3. Incorrect ordering

  4. Lack of quality control

  5. Lack of quantity control

  6. Improper storage locations & methods

  7. Duplicated ordering & delivering

  8. Aged, obsolete equipment, material, methods

  9. Improper handling – Forced deterioration
  10. Uncontrolled growth
Challenge2 – Set In Order – “Seiton”

Objective:- Locate a specific place for a specific item with the specific quantity, near to the place where it’s needed – improved material & information flow(DEVELOP)

     Question:- What actions should “SET IN”?


       Team based work groups “engage” in counter measures for the identified opportunities from the Process Map

       Start analyzing the Material and Information flow – VSM

       Set in order the standards of the admin areas

       Set in order the standards of the processes – minmax, TIMWOOD

       Set in order the standards for the people

       Set in order a Visual factory to surface problems

       Quick Change Over story boards

       Create OPL’s for training on the set in standards

       Build Upon the Culture of Problem Solving – Why? Why?, plans to train every one on problem solving tools

       Assessment team with a “How can I help you?” mindset

       Set in order a system to prevent SEIRI.

7 Seiton Principles

  1. Follow the FIFO method for material

  2.  Assign each item a dedicated location

  3.  All items & their locations should be identified by systematic labeling

  4. Place items so that they are visible to minimize searching time(frequently used, sometimes used, not used but must be kept)

  5. Place items so that agronomical conditions are addressed and can be handled easily

  6. Separate “Exclusive” from common

  7. Arrange the work place to cater flow – “Flow when you can, Pull when you can’t”

Challenge3 – Shine – “Seiso”

Objective:- CleaningContinuous Inspection with a Meaning(ENGAGE)

          Question:- How to “Shine”?


       Cross check OPL’s, continue creating the OPLs

       Establish Standards for CLIT

       Train team members on using the 5 Senses

       Provide specific tools for specified cleanings

       Establish cleaning schedules

       Address points of contamination – Error proofing

       Enable hard to access areas

       Fuguai Tagging system

       Slowly build in The JH Pillar of TPM

       TPM Story Board

       PM:AM ratio

       Lay the foundation for KK Pillar – PDCA

       “Don’t Clean Keep it Clean” Culture

       “I run, I Maintain” attitude

       Start  training team members according to the skill matrix

       Seiton Preventions, kaizens

Challenge4 – Standardize – “Seiketsu”

     Objective:- Consolidate Efforts, Set platform for Raising Kaizens(ENGAGE)

     Question:- What should be the standard?


       Establish the agreed upon best method

       Auditing & training to meet standard work

       Establish SOPs

       Establish revised KPI’s, targets for those who achieved

       Start job rotation to pre-condition team members mindset, multi skilling – kick off E&T Pillar aggressively

       Standards to reduce cost

       “I run I maintain”  attitude to “We run We maintain”

       Turn most visual displays to visual management

       Platform to Error proof, innovate

        Establish Early Management System to prevent shine

       “Never, ever walk by an Unsafe Act”

       Establish the Lean Org Structure to support VA layer

Challenge5 – Sustain – “Shitsuke”

Objective:- INSPIRE


       Establish the human system model for the plant

       Servant Leadership

       Aggressive catch ball on the Hoshin – Bottom up

       Elements of coaching and Job Instruction training for new employees to shorten the mindset change

       One system, one voice, one company, one vision

To be continued………….

Lean football

FIFA fever is catching the world fast. On the outside lean manufacturing and football world cup (Soccer world cup) has no link what so ever. But with my lean cap on, I had a look at the game. I found it funny. Below are some observations. Football fans, I by no means want to offend you. Just go through the list.
Huge amount of waiting time: Only one person controls the boll at once. All the other players and the referees are just waiting.
Tens of thousands of people watch the match on the ground, and millions are watching it on TV. They do nothing. Only watching. Huge amount of wasted time.
Huge amount of Transportation: The main objective of football(At least according to my little knowledge on the subject) is to hit the goal. Not to pass the ball here and there. But most of the time team never even thinks about going to the goal. They just keep on passing the ball from one place to another. Huge amount of transportation without adding value to the final outcome.
Defects: Finally when they are near the goal, only very few percentages of balls actually hit to the goal. This in my opinion is a defect. When this happens, you will have to start the game all over again. Everything done up to this point is of little value.
Tons of Ergonomic problems: Especially the noise those trumpets create is very irritating. I do not know how the players in the ground tolerate it. It is even very hard when you watch the match on TV. Definitely not nice.
Lots of underutilized human talents: There are large numbers of players in the bench. I saw best footballers of all time in the stands just watching the match. Maradona is not playing the game. Aren’t these guys wasting talent?
I can go on adding to this list. But for the time being let’s stop here.
But the game has use of some lean tools also (Surprise). It is worth mentioning.
There is a use of visual indicators (Only to indicate the bad things though) in the forms of Yellow and Red cards. So everyone knows what happens when these indicators are pulled out. Everyone has to come to the referee and start arguing with him J

In the field, everything has its place. They are well marked and maintained. Just like a 5S space. Very good to see when I have my lean cap on.
Just leave your though as a comment. Sometimes it is very hard to be a lean thinker.
Have a Nice Day!

Wow! It was amazing 8 – 8 – 8 – 8

I just finished watching opening ceremony of Olympics on TV. It is the best ever I have seen. Management, teamwork, creativity, innovation and thinking gone into planning and perfection of execution was absolutely amazing. It was a treat to watch.

PS: After seeing the perfection, coordination and creativity gone into the ceremony I will not mind buying a Chinese car next time.

Cheers Beijing 🙂

Lean Concept Blog Celebrates its birthday

I started lean concept blog on 1st of January 2006. Since then I have been writing about lean manufacturing and related topics and also about its concepts. So in few hours when the whole world is celebrating the New Year 2008, lean concept blog is also celebrating its second birthday and stepping into the third year of operation.

It will not be possible without all of you. Thanks for being with lean concept blog. I hope all of you will be with my blog in the years to come.

Wish you all the very best and a Happy New Year!

I was in India last week

Just a note for my Indian friends. I visited India last week to attend some official work. I found it is to be a very interesting place. People are also very interesting. I wish I met any of my blog readers. But I couldn’t. Anyway it was fun.

Sri Lanka will win the ICC Cricket World Cup

I am a cricket lover. So I thought of creating this quick post.

Congratulations Sri Lanka. You have played beautiful Cricket and YOU WILL WIN….

(Sorry My dear Australian friends)