A New Look at In-sourcing and Cell Layout Boosts this Manufacturer’s Capacity by 107%

Situation A leading supplier of forgings to Tier I and II aerospace, defense and automotive companies won a significant contract. As the company ramped up a new production process under the contract, they discovered their outsourcing operations … [Read more...]

Are Cobots Part of Your Plant’s Future?

How to begin with Lean Robotics “You’re still gonna have to have the people here.  Somebody’s still gotta man that machine that’s supposed to be able to do everything. And tell us when that machine doesn’t want to work the way it’s supposed to.” … [Read more...]

How to Make Your Plant Reliable

Five basics to make your Lean and RCM programs play well together. The bottom line: Lean relies on takt time as the cadence for producing to meet customer demand. Takt time assumes that critical process equipment will be reliable (i.e., … [Read more...]

How to Succeed at a Gemba Walk Using the 3Gen Principle

Regardless of your industry, you may have observed (or actively participated in) the 3Gen principle, commonly known as a Gemba Walk. Do you and your team know how to truly prepare yourself for and succeed with Gemba Walks? First, a little … [Read more...]

The Other Approach to Lean

Product Quantity Analysis, the Process Matrix and the Spaghetti Chart Total Productive Maintenance, Six Sigma, Set-up Reduction or 5S methods may be used either separately or together to help a facility’s team define the best path to a lean goal. … [Read more...]

How to Set Up a Lean Factory That Works

Lean manufacturers have a leg up on speeding products to market, reducing costs and keeping customers happy. In this overview, I’ll share how to engineer, set up and manage the project for a lean factory that works for your specific … [Read more...]

How to Set Up a Lean Factory That Works – Part 2

How can a lean factory tollgate process work? Here is a sample tollgate path for re-working your facility’s layout – or setting it up from scratch. Read Part One Part 2 of Lean Factory: a 2-part series How Can a Lean Factory Tollgate Process … [Read more...]

Supporting A Client’s Lean Continuum with Value Stream Mapping

April was a very busy month for Daniel Penn Associates. In late March, we performed a high level strategic analysis for a medical device manufacturer. The focus?  Identifying part families for focused improvement efforts. Value Stream Mapping events … [Read more...]

From hype to adoption: Is your maintenance program ready for the IIoT?

You’ve read about the Internet of Things (IoT) and its subset, the Industrial Internet of Things (IIoT). Gartner’s recent Hype Cycle for Emerging Technologies has the IoT rising to what it calls The Peak of Inflated Expectations with an estimated … [Read more...]

Do’s and Don’ts for Making Process Improvements that Stick

What’s holding your maintenance organization back from making process improvements? … [Read more...]