How total productive manufacturing can unite the shop floor and increase efficiency.
By Gregg Messel, Robert Burke and Patrick Lucansky. Total Productive Manufacturing (TPM) is a customer focused approach to business aimed at satisfying both the customer and the company's need. The TPM partnership between production and maintenance is designed to improve or eliminate the nine major categories of equipment losses.
Maintenance Versus Production
Key lean components in a regulated environment.
By Larissa Potapchuk and Patrick Lucansky. As organizations identify opportunities for growth and improvement, successfully managing activities to realize these opportunities is critical for achieving results and benefits. Effective project management starts with the application of key principles and tools in order to increase the likelihood of success of the initiative, regardless of whether the intended improvements are focused on strategy, products, processes, or technology.
Effective Project Management
Quality – What does it really mean to you, your organization and your customers? (Part one of a two part series)
By Ian Nicholls with Robert Burke and Patrick Lucansky. Quality means different things to different people. A hand made shirt, a silk scarf, a designer dress, a tailored suit, Italian leather shoes, Spanish leather handbags, a Swiss watch, an expensive perfume, scented soap, a luxury car, a wine from a year of good vintage and a fine liqueur are all examples of what are thought of as quality items.
Quality Part 1
What does it really mean to you, your organization and your customers? (Part two of a two part series)
By Ian Nicholls with Robert Burke and Patrick Lucansky. Overcoming the misconceptions introduced earlier, and creating a positive environment, requires a formal structure of management organization, education, communication and training.
Quality Part 2
Total Productive Manufacturing
The evolution of a maintenance based tool to a critical operational construct.
By Gregg Messel, Robert Burke and Pat Lucansky. Traditionally, the role of maintenance has been to fix the equipment when it broken down. This " reactive" mode means that the machine always seems to be broke at the "worst possible time". TPM Article
A review of the Drug Safety process from a Lean perspective.
By Pat Lucansky and Robert Burke. Drug Safety (Pharmacovigilance) is the practice of receiving, reviewing, assessing and reporting adverse events from drugs produced and administered during the different phases of clinical trials and post-marketed studies. The main objective of Pharmacovigilance is two-fold; (1) Legislative Compliance, Periodic Safety Updates, Registration, SERM, Product Safety Updates, CIOMS and Medwatch and (2) Protect the patient and the company.
Back from the Brink
From Simulation to Implementation, a lean success story in a regulated industry.
By Gregg Messel, Pat Lucansky and Robert Burke. In November of 2001, a $100 million Division (former Shingo prize winner) of a $2 billion Corporation, in San Antonio , Texas ( USA ) realized they needed help, they had lost their way. To make matters worse, the management team had recently left the company and many of the past improvements had disappeared as well.
From Simulation to Implementation
A pharmaceutical suppliers' successful Lean Journey.
By Robert Burke and Gregg Messel with Patrick Lucansky. Faced with increasing customer pressures to reduce costs and the downward spiral of sales, they had to make some immediate, serious decisions. They realized (with the assistance of their outside consultants) that they were overstaffed in all areas of the business, the internal cost structure was increasing as was the dependence on long lead times, higher levels of inventory and high levels of scrap.
Simulation at Work
A VIP Simulation Lean Workshop is used in this article as an example of lean training.
Business simulations help people learn to apply lean concepts---Beyond the factory floor. Article from Industry Week on best practices.
A lean approach to meeting internal and external regulatory requirements.
By Pat Lucansky, Larissa Potapchuk, Robert Burke and Ed Pokropski. Is 'Lean Compliance' an oxymoron, or is it compliance at any cost? Can an organization be lean and compliant without compromising quality and customer service? Many life sciences organizations are wrestling with these dilemmas as profit margins get squeezed and regulatory bodies stiffen compliance requirements.
Preparing For Success in an Organization Transitioning to Lean Management.
By Lucansky, Potapchuk and Burke. Training systems in a lean environment are discussed with an emphasis on designing and implementing a robust, dynamic program geared toward educating and inspiring a workforce.
A Framework for Making the Transition to Lean.
By Lucansky, Potapchuk and Burke. Lean transformation is a lengthy, gut-wrenching journey for any company. The expedition can be fraught with many perils; disillusionment, missed expectations, cost-overruns, lost business, and worst of all, unemployment. The authors discuss the pitfalls, benefits and methods for transforming an organization.
What is it and why is it essential to business survival in the new millennium?
By Lucansky, Ducharme and Burke. Lean tools and techniques are deployed throughout the business from customer service to manufacturing to finance to distribution. Through the elimination of "waste" (non - value - added activities) identified in value stream mapping, companies can reap huge benefits.
Why can't we get it right?
By Lucansky, Ducharme and Burke. This article discusses the role metrics plays in shaping and driving behaviors from a strategic, operational and tactical viewpoint. Performance Measurements
Performance Measurement Systems
The Decision Making Process in the Value Chain
By Lucansky and Ducharme. This article explores how lean companies use the decision making process to effect change in the value stream through traditional thought and integrated techniques of gathering, sorting and validating information.
Decision Process - Value Chain
By Ducharme and Lucansky.
The authors discuss how product flow, customer demand, information flow, customer/supplier linkages and cash flow all come together to structure, drive and control such functions as procurement, logistics, and production providing a seamless process. Lean Supply Chain Article, ASP Case Study
Design Engineering for Lean Operations
By Ducharme and Lucansky.
In this article, the authors postulate a lean, integrated product development process model where design of experiments, design for manufacturing and assembly, the DMAIC methodology of six sigma and value streaming are key drivers through internal cross functional teams integrating customers and suppliers. Lean Operations. Design Engineering
A Total Cost of Ownership Approach
By Ducharme, Lucansky and Burke. With the emergence of Lean Enterprise as a strategic initiative, organizations are developing selling prices through a robust and cross functional analysis of markets, competitors, products and processes. Target Costing
Lean Cross Functional Team Process
What's all the buzz about?
By Lucansky, Potapchuk and Burke. For teams to effectively change behaviors and hence corporate culture, they must be structured and follow a disciplined approach like the DMAIC methodology of Six Sigma. The authors establish a format and process for developing these high powered teams. Lean Team
A model for the new millennium.
By Lucansky, Potapchuk and Burke. The classic leadership/management dilemma is discussed. The authors pose a model for leaders to follow to provide the necessary leadership to their lean journey. The paradigm shift moves from a traditional, hierarchical model to a lean structure where the leader acts as a strategic orchestrator. Lean Leadership
What Is It and Why It Is Essential to Business Survival in the New Millennium
By Patrick Lucansky and Robert Burke. Lean tools and techniques are deployed throughout the business from customer service to manufacturing to finance to distribution. Through the elimination of "waste" (non - value - added activities) identified in value stream mapping, companies can reap huge benefits.
The Lean Enterprise
What is Lean Enterprise?
What is this thing called Lean?
By Patrick Lucansky & Robert Burke. Is it different from JIT, TQM, Re-engineering or World Class? Why do we need to change the way we are working, we are profitable? Are these questions that have crossed your mind? Many have wrestled with these and other similar concerns over the last couple years. The first thing we need to do is understand what Lean is all about.
Supply Chain Redesign
Advanced Sterilization Products (ASP), a Johnson & Johnson Company - A success story in a regulated environment.
By Haase, Ducharme, Lucansky and Stadnick. A case study in the redesign of ASP's supply chain process through strategic partnering models, JIT techniques, Six Sigma and Lean concepts. ASP deployed a structured, disciplined supplier/parts qualification process to dramatically reduce lead - times, costs, errors and waste while utilizing a lean supply chain simulation training workshop to energize and motivate cross - functional teams. Supply Chain Redesign