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| Logistical inefficiencies in loading/unloading, truckage, warehousing, etc., often contribute more to unrecognized waste in operations than the production work itself. Being a labor-intensive process, logistics is one of the most difficult aspects of an operation to manage and is, therefore, where Kaizen activities are most needed, and often result in the most dramatic improvement. |
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| The first step for our consultants is to set up work groups at each phase of the logistics system. We then ask them to analyze their own procedures to identify problem areas. Next, we dissect each problem (scheduling, ordering, materials, products, information flow, etc.) and help your staff develop and integrate strategies for improvement, through Kanban and Heijunka methods, if appropriate. By allowing your logistics staff to identify problems and implement their Kaizen ideas immediately, the rewards of their effort are immediately apparent. This motivates staff to pursue Kaizen methods under their own initiative, which benefits the entire organization. |
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The approach taken for logistics Kaizen differs depending on the targeted process:
- In-house logistics (same site)
- In-house logistics (off site)
- Supply-chain (various material vendors involved)
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| Kaizen activities in-house are fairly easy to implement because effects from the outside system can be minimized and the same systems can be implemented even though outside vendors might transport materials between sites. Supply-chain management, however, requires integration of Kaizen activities between staff in both internal and external systems. Our consultant will analyze each link of the supply chain, including multiple systems integration, and develop solutions to address each element's specific problems. |
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