When Layout Is the Real Problem If your plant feels like organized chaos – constant firefighting, late deliveries, excess WIP, increased operating costs despite process improvements – odds are the layout is part of the issue. Many manufacturers try to solve missing delivery dates, fighting WIP pileups, or spending too much time (and money) moving…
A3 thinking sounds like a fancy tool. It’s not. It’s a discipline. At its core, A3 thinking is just a structured way to solve problems on a single sheet of paper. But in practice, it teaches teams how to think, collaborate, and improve. This makes it one of the most effective lean problem-solving methods and…
Manufacturers are obsessed with waste. Scrap. Downtime. Defects. All of it matters. But in my experience, the biggest waste is the one almost no one talks about: not using the knowledge and capability of your people. The Manufacturing Waste You Don’t See You walk into a plant and see the usual problems: quality issues, long…
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