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Russell Watkins - The Lean Expert
Великобритания
Добавлен 19 авг 2020
Welcome to Sempai - Russell Watkins
Where we help you use lean techniques to create truly great factories. Our videos are full of practical lean tips to help you beat the Operational Issues hindering the growth of your manufacturing business. Our practical lean guides are the result of 25 yrs working with the best manufacturing businesses and minds in the world.
FREE GUIDES
▶ Hoshin Kanri 3 Step Process www.sempai.co.uk/hoshin-kanri
▶ 10 Ways to reduce your costs www.sempai.co.uk/10-ways-to-reduce-costs
▶ 5s checksheet www.sempai.co.uk/5s-checksheet
▶ 10 Ways to Make Standard Operating Procedures (SOP) Better. www.sempai.co.uk/sop-example
ABOUT
Russell is a lean expert. He set up Sempai with his wife and co-founder, Steph, in 2007 and has designed and run multi-site lean programmes for Toyota Group, created the JCB Production System & established two Accredited Lean Academies. Steph is 'process & strategy', a management accountant turned marketer.
Where we help you use lean techniques to create truly great factories. Our videos are full of practical lean tips to help you beat the Operational Issues hindering the growth of your manufacturing business. Our practical lean guides are the result of 25 yrs working with the best manufacturing businesses and minds in the world.
FREE GUIDES
▶ Hoshin Kanri 3 Step Process www.sempai.co.uk/hoshin-kanri
▶ 10 Ways to reduce your costs www.sempai.co.uk/10-ways-to-reduce-costs
▶ 5s checksheet www.sempai.co.uk/5s-checksheet
▶ 10 Ways to Make Standard Operating Procedures (SOP) Better. www.sempai.co.uk/sop-example
ABOUT
Russell is a lean expert. He set up Sempai with his wife and co-founder, Steph, in 2007 and has designed and run multi-site lean programmes for Toyota Group, created the JCB Production System & established two Accredited Lean Academies. Steph is 'process & strategy', a management accountant turned marketer.
5s in 60 seconds
5s in 60 - with a real definition. How 5s helps you in your factory
It helps your team to focus on making good quality parts and to see when things go wrong.
What are the 5s's?
1. Sort
2. Set
3. Shine
4. Standardise
5. Sustain
It helps your team to focus on making good quality parts and to see when things go wrong.
What are the 5s's?
1. Sort
2. Set
3. Shine
4. Standardise
5. Sustain
Просмотров: 103
Видео
Visual Management Examples : Easy to apply
Просмотров 3903 месяца назад
Apply these Visual Management Examples to your factory Visual management isn't just some fancy buzzword - it's like a secret sauce for making your team unstoppable. Imagine turning your workspace into a place where everything flows smoothly and everyone's on the same page. Well, that's exactly what visual management can do for you! In this RUclips video, we're diving into: 🔎 The secrets behind ...
How to create a skills matrix : The easy Way
Просмотров 4,2 тыс.5 месяцев назад
Learn how to create a skills matrix the easy way with our skills matrix walkthrough. We take you step-by-step through the process of using our Skills Matrix to optimise your team's performance. With our Skills Matrix, you'll be able to identify strengths, weaknesses, and skill gaps within your team, empowering you to make data-driven decisions that drive success. Whether you're a small startup ...
Creating standard operating procedures : QUICKLY
Просмотров 7857 месяцев назад
Creating standard operating procedures doesn't have to be a long drawn out process and in this video, we show you (with an SOP example) that it can be done quickly. Standard Operating Procedures don't have to be perfect so don't let that put you off from starting. Follow our simple steps and download our SOP template to create great SOP's quickly. LINKS ► The basics of a stable operation ruclip...
Lean principles - The power of a new approach
Просмотров 2597 месяцев назад
Lean Principles often use a Top down or bottom up approach (2 different ways of implement lean). In this video we explain the power of marrying the two with Hoshin. Engaging the power of all the brains in the business to leverage the creativity they have to create kaizen & drive the business forward. LINKS ► Lean principles - why you're struggling with your transformation ruclips.net/video/ZOKj...
Lean Manufacturing Principles - why you're struggling with your transformation
Просмотров 3887 месяцев назад
Knowing Lean Manufacturing Principles is all well and good but unless you know what good lean principles are and how to apply them, you’ll struggle with your lean transformation. In this video we look at the 5 lean manufacturing principles: 1️⃣ Value 2️⃣ Value Stream 3️⃣ Flow 4️⃣ Pull 5️⃣ Perfection (from : Jim Womack and Dan Jones) Whilst the model is good, there’s still a piece missing. That ...
Gemba Walk : A beginners guide
Просмотров 1,3 тыс.8 месяцев назад
Gemba Walk: A practical guide for beginners and those want to improve the way they walk the gemba. In this video we look at what the Gemba is, how to walk it well and what you should be looking for when you do it. LINKS ► A walk around a factory with a lean sensei www.sempai.co.uk/walk-with-lean-sensei ► What is a gemba? walk ruclips.net/video/9qMTDMgDdTA/видео.html ► Walk the gemba with someon...
Lead time v cycle time v takt time : Unlocking the secrets to boost productivity
Просмотров 1,8 тыс.8 месяцев назад
This video looks at lead time v cycle time v takt time, definitions and the differences between them. Cycle Time is calculated with a stopwatch and is how long it takes to do the work at each operation in the process. Whilst takt time is a calculation and is defined as how frequently we need to produce a part off the end of the manufacturing process to satisfy the customer. We use a basic value...
How to calculate Lead Time. The easy way.
Просмотров 1,1 тыс.9 месяцев назад
Learn how to calculate Lead Time with a simple example. In this video we show you how to calculate Lead Time, using a simple lead time formula. We use a basic value stream map as an example to show you how long it takes to get a part through a factory from supplier to customer and all the processes in between. Don't forget to subscribe to our channel for more insightful content on process impro...
How to calculate Takt Time. The easy way.
Просмотров 3869 месяцев назад
Learn how to calculate Takt Time with a simple example. In this video we show you how to calculate Takt Time, using an example. Calculating Takt time can seem daunting but using our simple takt time formula you will be able to replicate the takt time calculation in your own factory. We'll show you all the information you need to calculate Takt Time for your factory. Including how to calculate t...
Continuous Improvement Kaizen : How to find kaizen examples in your factory
Просмотров 77010 месяцев назад
Learn how to find continuous improvement (Kaizen) through a real life factory example. we watch Jim working his normal shift and unpick . 🚀 In this video we discover the art of continuous improvement (Kaizen) in action! We dive into a real-life factory scenario where we shadow Jim during his daily routine. 🏭👷♂️ Unpicking the waste that is baked into his day to day work Join us as we unravel th...
What's coming up on our YouTube channel
Просмотров 3310 месяцев назад
Over the coming weeks we'll be posting new videos on Kaizen, Takt time calculation, lead time calculation and the difference between take time, cycle time and lead time.
Learn Lean Manufacturing
Просмотров 359Год назад
Welcome to our RUclips Channel. I’m Russell Watkins from Sempai where we show you practical lean techniques to help you to supercharge your manufacturing business. I started this RUclips channel to encourage people to apply lean and to show how simple lean techniques can have a big impact to your business. Most important is to have a go On this channel I’ll be releasing regular videos covering ...
7 Step Problem Solving : The mistakes to avoid
Просмотров 483Год назад
7 Step Problem Solving. Learn the steps and the common mistakes to avoid! In this video, we run through exactly what the 7 step problem solving process is and how you can put it to good use in your business. We also give you 3 bonus tips to supercharge your problem solving. This video covers all the major 7 steps in the problem solving process: 1. Grasp the current condition 2. Locate the proce...
10 ways to make a good Standard Operating Procedure (SOP) quickly.
Просмотров 1,8 тыс.Год назад
10 practical ways to make your SOP better, quicker. In this video, we'll guide you through the key elements of a good Standard Operating Procedure (SOP), also known as a Standardised Work Instruction (SWI). We'll showcase practical SOP examples that have been proven to work across various industries, empowering you to apply these principles in your own organisation. Join us as we unveil the sec...
How to complete an hourly production board well
Просмотров 1,1 тыс.Год назад
How to complete an hourly production board well
What's the best way to get your Hoshin kanri working properly?
Просмотров 203Год назад
What's the best way to get your Hoshin kanri working properly?
Will we still need people in an automated factory?
Просмотров 143Год назад
Will we still need people in an automated factory?
Line Balancing : 3 line balance metrics
Просмотров 499Год назад
Line Balancing : 3 line balance metrics
Lean Manufacturing - Adhere to start, finish and break times
Просмотров 125Год назад
Lean Manufacturing - Adhere to start, finish and break times
Lean Management - 3 Basic Golden Quality Rules
Просмотров 1662 года назад
Lean Management - 3 Basic Golden Quality Rules
Lean Management - Inventory Storage Areas
Просмотров 1882 года назад
Lean Management - Inventory Storage Areas
Lean Management - Separate good products from defects
Просмотров 1122 года назад
Lean Management - Separate good products from defects
This is great Russell, thank you. I am creating my own and this gives me some great ideas. Thanks!
Great - I'm pleased it was useful Nate - keep it simple!
Hi Russel! Thanks for the valuable information. Does this include the skills for the setup processes in the machines? E.g. , changing belts in a pulley, or something along those lines. Thanks!
Hi there. It can include those things. Truth is it should reflect whatever your needs are in terms of skills flexibility and the skill required to make good parts safely. Just be careful of being too granular
Excellent video Russell. As ever!!👏
Glad you enjoyed it
What if we factor in transportation, ?
Hi - it depends what we want to achieve and how the transport is managed. If the aim is to measure and improve the amount of transportation waste between processes - we can do that during the observation of the current line balance to tackle in the rebalance. If the operators themselves are having to transport processed parts elsewhere (rather than just passing to someone stood next to them) we’d include that time in that operators cycle time(as its activity they’re stop having to do). Is that what you meant?
I disagree with materials control on leaders, sometimes vendors provide poor quality parts / components and it affects the final assembly process with downtimes, scrap, etc. In other cases, the company decides to buy raw material on a lower price and in consequence on a lower quality. Good video!
Hi - I agree that not all materials issues are within their control but they can and should control some material cost losses - the ones they cause. I often see those 2 problems you mention. Quite right - a shop floor leader neither causes nor is responsible for resolving them. The part they’ll play is giving good data about when and how many times they get these problems.
Good points and examples!
Thank you
Excellent video. The marriage of lean and Industry 4.0 will become an increasingly important topic.
Thanks Marco, howe we manage this with people at the centre is the key. You might enjoy this blog about Toyota's thinking www.sempai.co.uk/post/toyota_digital_manufacturing
Thanks for the tips about visual management boards. Where I work, there’s too much information and too much visual boards that are not being filled with the correct information; it seems to me that these boards were put there just to be up to date with the requirement for auditing but it’s main objective or it’s purpose just misses completely. Instead of bringing support to the team leaders, it just gives them too much work for them to handle. And I’m trying to find a way to simplify those boards without removing some of the requirements that need to the board to be on the standard.
Hi - it's a problem almost everywhere I go. Either no boards or too many with too much on. Becomes a vicious circle as TLs can't keep up with the boards and run their patch at the same time. I know it's tricky to challenge management sometimes as well. I start with asking the purpose of each thing on the board and looking for duplication OR where nothing is done with the information. From your comment I'm guessing you'll agree that data is only useful if something is done with it so I'd be asking who uses it. I also try to embed a 1 in 1 out policy early on. Boards can be useful but too many and line of sight is knackered (as well as the burden of updating & reacting to them all). 1 in 1 out forces a discipline of only being able to put a board up if one comes down to make space...at least then there's some pause to decide if all this data is needed. I rarely see any TL patches that need more than 1 decent sized or 2 small boards to monitor SQDCPE, control it and find kaizen.