Inventory – Lean Smarts

The Role of the Lean Water Spider (Overview)

Inventory, Kanban, Water Spider / Example, Instruction, YouTube

Understand the role of a water spider for replenishing inventory and kanban throughout the manufacturing floor.

Line Side Delivery Design Principles

Inventory, Kanban, Water Spider, Work Cell Design / Example, YouTube

Overview design features of line side delivery of inventory. This typically utilizes kanban systems and a water spider (logistics team member) to replenish parts.

The Two Bin System (Kanban) at Seating Matters

FIFO, Inventory, Kanban, Standardization / Example, Instruction, YouTube

See how Seating Matters sets up its two bin kanban system for inventory handling. In 2020 they made a major switch over to this system as a superior way of simplifying and standardizing inventory replenishment.

How Kanban Works at Seating Matters

Inventory, Kanban / Example, YouTube

See how the kanban system works at Seating Matters. See how kanban cards are used along with 2 bin systems and ordering practices. By the way, all kanban are laminated in standard A5 laminating pouches.

One Piece Flow in a Finishing Room Example

Inventory, Motion, One piece flow, Over Production / Example, Instruction, YouTube

See this well demonstrated and explained application of one piece flow in a finishing (paint) room in a cabinetry business. Converting from batch to flow might be a mental block at first, but yields amazing results when perfected!

Envelope One Piece Flow Simulation at Gemba Academy

Inventory, Lead Time, Motion, One piece flow, Over Production / Example, Instruction, YouTube

See the difference between batching (over production) and one piece flow in this envelope stuffing simulation performed by Gemba Academy. Over production increases both motion and inventory wastes in this example.

Large Part Conveyance at Seating Matters

Inventory, Kaizen, Transportation / Example, YouTube

See this improvement from April 2020 to provide a means of transporting large parts at Seating Matters. Large part conveyance can be a special challenge. Until a solution is provided, they often rest on the floor and get confused with the production schedule or even damaged.

Fundamentals: Value Stream Mapping (VSM)

Inventory, Lead Time, Value Stream Map (VSM) / Instruction, Lean Smarts

Understand how a value stream map (VSM) is used to map the flow of production, identify bottlenecks and opportunities for improvement. A VSM analyzes the entire value stream from start to finish and exposes inventory wastes and non-value-adding time.

Fundamentals: SMED (Quick Changeover)

Inventory, Over Production, Production Leveling, Quick Changeover / Instruction, Lean Smarts

Learn how to accomplish a quick changeover, also known as “SMED” (single minute exchange of die). Quick changeovers are necessary in order to increase production mix, reduce batch sizes, avoid over production, achieve better production leveling, and unlock additional capacity.

Fundamentals: Pull Systems

FIFO, Inventory, Kanban, Over Production / Instruction, Lean Smarts

Learn about pull systems of all kinds including FIFO lanes, 1-card kanban, and 2-card/bin kanban. See the difference between push production and pull production. Understand when and why pull systems are necessary to promote good flow.

Overcoming Inventory Challenges with 5S and Kanban | Episode 5

Inventory, Kanban, Straighten / Documentary, Example, Instruction, Lean Smarts

Inventory management was a key problem when opening up the donut shop. It consumed a TON of Daniel’s brainpower and attention and had to be dealt with early on so that he was free to focus on other problems and leading the donut team. We eventually setup a kanban system to serve as our purchasing system.

The LEAN Donut Shop! Lean Documentary | Episode 1

Defects, Inventory, Kaizen, Motion, Over Processing, Over Production, The 8th Waste, Transportation, Value vs. Waste, Waiting / Documentary, Instruction, Lean Smarts

We introduce the Lean Donut Shop and take you to the donut kitchen where we expose employees to the concepts of VALUE and WASTE for the very first time! You will discover the 8 wastes of lean, define “value,” and realize why respect for people is foundational for building a lean organization. Learn with us at the gemba with real examples, spontaneity, and humor!

10 Kaizen “2 Second Lean” Improvements in 4 Minutes

3S, 5S, Inventory, Kaizen, Motion, Shine, Standardize, Straighten / Example, Lean Smarts, YouTube

Discover our 10 latest “2 second lean” kaizen improvements at home in the spirit of Paul Akers. Show others how simple and fun it is to do lean!

Fun Lean 5S Capsule Closet for Easier Laundry

3S, 5S, Inventory, Sort, Straighten / Example, Instruction, Lean Smarts, YouTube

Discover how 5S and reduced batch sizes make a world of a difference for doing the laundry! We gutted out our closet and reduced the selection and number of items considerably following inspiration from the “capsule” concept and lean concepts of 5S and batch size as it pertains to flow and the waste of overproduction.