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What is Lean?

The term ‘Lean’ was coined in the 1990s in the Womack and Jones best seller The Machine That Changed the World: The Story of Lean Production. The book chronicles the transitions of automobile manufacturing from craft production through mass production to lean production. It revealed how the Toyota Production System (TPS) had transformed a small post-war Japanese concern into the most successful car company in the world.

The core aim of Lean is to eliminate non-value-adding activities (those which the customer would not want to pay for), to compress time and to create competitive advantage by optimising the use of limited resources (people, space, capital).

Toyota’s success was remarkable – in the 1980s a Toyota took 17 hours to build and was ready to be shipped. A Mercedes spent that time in the rework area alone.

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What is Six Sigma?

‘I don’t even know what a sigma looks like – so why would I want six of them?’

Since Motorola pioneered it in the 1980s, Six Sigma has become popular in many sectors. It is not hard to see why when one looks at its primary claim: defects reduced to 3.4 per million items produced. Thousands of businesses have spent millions of pounds, yen, dollars and euros implementing Six Sigma programmes.

The objective of a Six Sigma philosophy (programme, culture, project, etc) is to manage variability. Without variability, any business would improve dramatically. It affects customer service levels, costs and delivery performance.

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5 Classic Efficiency Mistakes

Get a group of managers together and discuss Lean or Six Sigma improvement and one of the few things you are likely to get them to agree on is that measuring efficiency is a good start. Among the many options, OEE is a popular and powerful measure for businesses across a range of industries – so how can such a simple and powerful tool lead so easily to complacency?

Complacency? Surely it’s the yardstick against which all progress is measured? In theory, yes, but experience shows that there are some very simple traps that many organisations fall into when measuring efficiency which can have a profound negative effect on improvement in the organisation. Let’s look at the 5 most common ones…

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Testimonials

It’s brilliant! We used to produce 3 or 4 full bins of waste a day now we’re down to less than ½ a bin! The final bit of work we do should reduce it to virtually nothing!

Operator – Branded Bakery

Inspiring the people in our business to understand how they can improve and the business can therefore develop, is an important building block in our drive for improving efficiency within our business. Engaging everyone in the business to realise that we can be better and any little improvement drives down to the bottom line. This has been seen both in the way the staff have engaged and enjoyed the experience and the evidence of reduced costs has helped the business to become more efficient. This process never stops but it is the tools that have been developed by Lauras International that has allowed us to deliver this important work at both our potato pack houses.

Fraser Scott, Head of Farming Operations Arable/Potatoes