Amazon

Continuous Improvement Manager

Area Manager

Site Manager

Junior Site Manager

Syddansk Universitet - University of Southern Denmark

Junior Research Assistant

Kverneland Group Kerteminde A/S

Master Thesis Project

ForeFlight

Data Consultant

Odense University Hospital

Semester Project

Follow for daily posts about Lean, CI & Innovation | Continuous Improvement Manager @ Amazon

Hi! 👋 Ivan here.

I'm an industrial engineer with 5+ years of experience in Operations Management.

I'm currently working as an outbound manager at AMXL First Mile Operations, Amazon. In December 2022, I accepted a stretch role as a CI facilitator to promote a culture of Continuous Improvement within AMXL.

As a lean practitioner and innovation enthusiast, I thrive on navigating the dynamic landscape of E2E Supply Chain Management. 

My journey in operations has been marked by a relentless pursuit of operational excellence, and a passion for cultivating a workplace culture that values continuous improvement. 

Innovation isn't just a buzzword for me – it's a way of thinking. I'm used to driving innovation by embracing Industry 4.0 technologies and encouraging creative problem-solving to stay ahead of industry challenges.

I started writing on LinkedIn in October 2023. Since then, I have been posting around: 

- Continuous Improvement
- Lean Manufacturing
- Growth Mindset
- Innovation

Including insight on: 

- 5S
- VSM
- Kaizen
- Leadership
- Industry 4.0
- Data Analysis
- Lean Six Sigma
- Problem Solving
- Process Improvement

I share actionable, educational, and entertaining content to support LinkedIn community members in their CI journey.

I'd love to connect if you share a passion for operational excellence, Lean methodologies, and the thrill of driving innovation.

Best,
Ivan

How to outline the operators' workflow during a work cycle, get a comprehensive view of their activities, and cut non-value-added ones:


Standardized Work Combination Sheet (SWCS) is a critical Lean tool. 
 
It integrates various timing elements
 
+walking time 
+manual work time 
+machine processing time 
 
And visually represents the sequence of tasks, 
their timing, and resource utilization in a specific process. 
 
KEY COMPONENTS
 
Operator Details 
 ↳ Information about the specific operator being analyzed 
 
Takt Time 
 ↳ The required cycle time to meet production demands 
 
Time Measurements 
 ↳ Detailed breakdowns of time spent on various activities 

BEST PRACTICES

Involve Operators
 ↳ Develop the sheet with input from those performing the work

Regular Updates
 ↳ Treat the document as a living tool

Visual Clarity
 ↳ Use clear, action-oriented descriptions for each step

Accessibility
 ↳ Post the sheet in the work area for easy reference

TL;TR

SWCS provides insights into workload management and process efficiency. 

Leverage it.
 
*** 
Credit: Nilson

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Ivan Carillo

Do you wanna start your Continuous Improvement journey?
 
Learn to see the 3M's of Lean.
 
The 3M's of Lean refer to 
 
+Muda
+Mura
+Muri
 
Three Japanese terms are used in the Toyota Production System.
 
These concepts are key to identifying waste in your processes.
 
Here's a brief overview of each:
 
1/ Muda
 ↳  Any activity that consumes resources without creating value for the customer. 
 
There are 7 types of Muda:
 
+Overproduction
+Waiting
+Transportation
+Over-processing
+Inventory
+Motion
+Defects
 
Muda can be further classified into:
 
Type I: Muda which cannot be eliminated immediately
 
Type 2: Muda which can be eliminated quickly through Kaizen 
 
***
2/ Mura
 ↳  Unevenness or inconsistency in operations
 
Mura can be seen as variation in quality, cost, or delivery.
 
It often leads to Muri and Muda.
 
Mura can be reduced by
 
+creating standard work
+levelling production schedule
+improving supply chain visibility
 
Unevenness in workload can cause periods of overburden followed by periods of waiting.
 
***
3/ Muri
 ↳  Unreasonable stress or burden placed on workers and processes
 
Overburdening people or equipment can be due to
 
-unsuitable tools
-poor design of work
-unrealistic expectations
 
Muri often results in safety and quality issues.
 
***
The 3M's are interconnected -
 
Eliminating one type of waste often requires addressing the others.

***
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Keep It Simple, Stupid!
 
 
KISS is a design principle that emphasizes simplicity over complexity.
 
Most systems work best if they are kept simple.
 
So, simplicity should be a key goal. 
 
KISS is based on the idea that simpler solutions are generally more robust, easier to understand, and less prone to errors.
 
The principle advocates for a straightforward, minimalistic approach to design and problem-solving.
 
Prioritize the essential features and functionalities, while avoiding over-engineering.
 
It's widely applied in various fields:
 
+problem-solving in general
+software engineering
+product design
+architecture
 
KISS is a guiding principle for creating user-friendly, maintainable, and efficient systems or solutions.

Inspired by Ulrich

***
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Poka-Yoke 
 
Level: PRO 

Poka-Yoke is a Japanese term that means "mistake-proofing".
 
It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur.
 
Key Advantages:
 
+Cost Reduction
+Error Prevention
+Quality Assurance
+Operational Safety
+Process Simplification
+Continuous Improvement
 
Poka-yoke methods often simplify systems and processes. 
 
They can lead to: 
 
+faster setups 
+work easy to do 
+clearer instructions 
+low training requirements

No need for disruption.

1% better. Every day.

Kaizen is the way.

***

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Master CI to keep your business ahead in 2024.

Go from zero to pro with this cheat sheet: 

1/ The PDCA Cycle

It's a fundamental tool for CI in areas such as 

+problem solving
+quality management
+new product development
+business process management

It enables you to solve problems and 
implement solutions in a rigorous, systematic way.

***
2/ Value Stream Mapping

VSM isn't just a Lean tool.

 It's the key to your business success.

VSM aims to show you where you can reduce waste.

It visualises your operations from material inputs to customer delivery. 

***
3/ 5S

It refers to five Japanese terms which are used to describe 
the main steps of visual management toward OpEx: 

(1S) Seiri → Sort 
(2S) Seiton → Set In Order
(3S) Seiso → Shine 
(4S) Seiketsu → Standardize 
(5S) Shitsuke → Sustain 

When successfully implemented, 5S can turn any dirty place 
into a clean, standardized workplace. 

***
4/ Gemba Walk

See the reality on the ground, instead of just relying on data. 
 
That’s what the Gemba Walk is all about.
 
In Japanese, the word ‘Gemba’ → ‘Actual Place.’ 

If you detect resistance to change,
switch to a go-see management approach.

***
5/ The 8 Wastes of Lean

Waste is something the customer is not willing to spend money on

Being able to see the wastes of Lean is always the first step.

TIMWOODS stands for

+Transportation
+Inventory
+Motion
+Waiting
+Overproduction
+Overprocessing
+Defects
+Skills

As you cut one waste, new opportunities for improvement will arise.

***

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Jidoka:
 
Injecting a human touch into automation
 
Jidoka is a key concept in Lean Manufacturing.
 
It's one of the 2 pillars of the Toyota Production System,
alongside Just-In-Time (JIT).
 
The concept originated with Sakichi Toyoda in 1896,
who developed an automatic loom that would
stop when the thread breaks.
 
The term can be translated from Japanese as
"automation with a human touch" or "autonomation."
 
Jidoka can empower workers and machines to stop
the production line when they notice an anomaly.
 
It prevents defects from being passed down the line.
 
Jidoka has two key components:
 
1/ Andon Systems
 
 ↳ Visual signals indicate when abnormalities occur
 ↳ Allow for quick identification and resolution of issues
 ↳ Minimize downtime by facilitating prompt responses
 
2/ Poka-Yoke Devices
 
 ↳ Prevent errors from occurring in the first place
 ↳ Simple physical designs or more complex electronic systems
 ↳ Help ensure consistent quality and reduce human error

***
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5-min master class on the PDCA cycle:
 

Kudos to Angad Singh for this interesting infographic.

PDCA is a four-step model for Lean problem-solving and change management.

Here’s a step-by-step review of the PDCA cycle:
 
1/ Plan
 ↳ Identify the problem or opportunity for improvement
 ↳ Analyze the current situation and collect relevant data
 ↳ Set clear, measurable objectives
 ↳ Develop a comprehensive plan to achieve your objectives
 ↳ Determine the resources needed and potential obstacles
 
***
2/ Do 
 ↳ Implement the plan on a small scale or as a pilot
 ↳ Document all actions and observations
 ↳ Collect data for analysis in the next stage
 
***
3/ Check
 ↳ Analyze the results obtained from the "Do" phase
 ↳ Compare the actual results with the expected outcomes
 ↳ Identify any deviations or unexpected results
 ↳ Determine if the plan was successful in achieving your objectives
 ↳ Look for areas of improvement or adjustment
 
***
4/ Act 
 ↳ If the plan is successful, implement it on a larger scale
 ↳ If not, modify the plan or develop a new approach
 ↳ Standardize brilliant processes and integrate them into regular operations
 ↳ Identify lessons learned for future improvement cycles
 ↳ Begin the next iteration of the PDCA cycle
 
***
Remember, the PDCA cycle is a loop, not a linear path.
 
Once the 'Act' phase is completed, 
go back to the 'Plan' phase to trigger the cycle once again.

Trying to stay organized in a chaotic workplace?
 
Learn 5S!

5S refers to 5 Japanese terms describing the main steps of visual management toward OpEx: 
 
(1S) Seiri → Sort
(2S) Seiton → Set In Order
(3S) Seiso → Shine
(4S) Seiketsu → Standardize
(5S) Shitsuke → Sustain
 
This methodology can turn any dirty place into a clean, standardized workplace.

Here are 4 mistakes to avoid during 5S implementation:
 
1/ Lack of Leadership Support
 
 ↳ Top management fails to support or participate in the process
 ↳ Leaders don't allocate sufficient resources or time
 
2/ Inadequate Training & Employee Involvement 
 
 ↳ Not engaging all staff members in the 5s implementation
 ↳ Misunderstandings lead to resistance or improper execution
 
3/ Rush the Process
 
 ↳ Trying to implement all 5S steps too quickly
 ↳ Not allowing enough time to execute each phase well
 
4/ Failure to Sustain 5S
 
 ↳ Not a one-time project. It's an ongoing commitment 
 ↳ Lack of regular audits and recognition programs

***
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Quick Management Tip:

Switch to a go-see approach.

Gemba Walk is key to enhancing your processes.

It's a management practice where leaders 
go to 'the actual place'.

Key Benefits:  

1/ Direct Observation
 
 ↳ Understand daily challenges
 ↳ Gather first-hand information

2/ Clear Communication

 ↳ Open dialogue b/w leadership & operators
 ↳ Workers feel heard and valued 

3/ Waste Identification

 ↳ Identify inefficiencies in processes
 ↳ Facilitate the implementation of improvements

Remember, the Gemba is where the truth is.

As a Toyota chairman said:
Go see, ask why, and show respect!

***
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Gemba Walk

The road to hell is paved with good intentions.
 
Master Troubleshooting to keep your business ahead in 2024:
 
Employees with strong problem-solving skills..
 
+earn 18% more on average than those without
+report 31% lower stress levels at work
+are rated 42% more effective by their teams
 
Here are 5 hidden pitfalls in problem-solving:
 
1/ The Cobra Effect
 
It refers to an example of an incentive gone wrong.
 
Delhi had a cobra infestation during the British Empire.
 
The government, concerned about cobras,
offered a bounty for every dead cobra.
 
This cash reward created a perverse incentive.
 
In the end, the original problem compounded.
There were more cobras in Delhi than ever before.
 
Key Aspects:
 
↳ Some solutions can have unforeseen negative outcomes
↳ Focusing only on KPIs can ignore important factors
↳ Long-term sustainability > Immediate results 
 
***
2/ The Iceberg of Ignorance
 
This theory suggests that in many organizations,
top-level management has limited visibility into challenges.
 
Those at lower levels have a more comprehensive
understanding of the issues.
 
Key Aspects:
 
↳ Info doesn't flow freely up the chain of command
↳ Disconnect between decision-makers and front-line staff
↳ Many issues remain unseen or unaddressed
 
***
3/ The River of Waste
 
This analogy describes a situation where your efforts
to solve problems may move them downstream.
 
It suggests you looking for the big rocks.
Pick no more than 3 or 4.
 
Then, tackle them one at a time.
 
Key Aspects:
 
↳ Failing to consider the long-term impacts
↳ Short-term gains may mask larger problems
 
***
4/ The Ostrich Effect
 
It's a cognitive bias where people tend to
avoid negative information.
 
It's like the myth of ostriches burying
their heads in the sand when faced with danger.
 
Key Aspects:
 
↳ Often driven by anxiety or fear
↳ Creating a false sense of security or progress
 
***
5/ The Baader-Meinhof phenomenon
 
It's an interesting cognitive bias that can have
Implications for problem-solving.
 
Once you become aware of something,
you tend to notice it more often.
 
Key Aspects:
 
↳ Seeing connections where they might not exist
↳ Disproportionate attention being devoted
 

***
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Hot take: 
Some organizations waste time trying to force VSM into their work environments.
 
Processes are digital and automated in modern manufacturing.
 
And VSM can oversimplify some processes or
miss critical digital interactions.

Makigami is a superior tool for administrative processes.
 
Here are the key differences:
 
1/ Scope
↳ VSM: Focuses on manufacturing and production workflows 
↳ MK: Concentrates on administrative and office processes
 
2/ Purpose
↳ VSM: Identifies waste in material and information flow 
↳ MK: Maps detailed human interactions and process complexities
 
3/ Level of Detail
↳ VSM: Emphasizes overall process efficiency and cycle times 
↳ MK: Provides a granular view of cross-functional interactions
 
4/ Visualization
↳ VSM: Horizontal linear representation 
↳ MK: Vertical multi-lane process mapping
 
5/ Use Cases
↳ VSM: Supply chain, manufacturing optimization 
↳ MK: Service industries, complex administrative workflows
 
The biggest mistake companies can make is using only one of them.
 
The future of process improvement lies in hybrid approaches.
 
Combine both methodologies.
 
***
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Value Stream Management isn't just a set of practices. 

It's the key to your business success.

Any business has one main goal:

Providing great value at the lowest price.

In line with this, Value Stream Management aims to 

+Identify the 7 wastes of Lean
+Improve your way to deliver high-quality CX

Value Stream Mapping (VSM) is a key component of Value Stream Management.

Here are 5 simple steps to create your Value Stream Map:

***

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 5 simple steps to create your Value Stream Map

How to automate complex business processes in 6 simple steps: 
 
  
1/ Establish Objectives 
 ⤷ Define clear objectives for your project. 
  
2/ Assess Current Processes 
 ⤷ Determine what can be automated. 
  
3/ Identify Tasks 
 ⤷  Determine your tasks & prioritize them based on importance, complexity, and time saved. 
  
4/ Develop Automation Plan 
 ⤷ Outline each process step, tools to be used, resources needed, and timelines. 
  
5/ Implement Automation 
 ⤷ Implement each element of the plan using appropriate tools and resources. 
  
6/ Monitor Performance 
 ⤷ Monitor the performance of the automated processes and optimize them as needed. 
  
Process Automation is pivotal to optimising your workflow.  
 
Figure out which technologies you can leverage to automate your manual process. 
 
*** 
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Toyota Production System

Myth vs Reality:

***
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Ops Leader: "That's the safest, easiest, and waste-free way to perform this process."

Their standardized work:

Glue is cheap. Leaks are expensive.


Smart professionals don't wait for problems.

They prevent them with simple, effective solutions.

Simple solutions create the most value.

***

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5-minute master class on SWOT Analysis:
 
(save this now)
 
The key to success is identifying your strengths, building on them, and compensating for your weaknesses.
 
When it comes to business and strategy, being proactive and aware matters.
 
It helps you make informed decisions and understand what’s happening inside and outside your business.
 
That's where SWOT analysis comes into play.
 
Here is a breakdown of each component:


***
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SWOT

Lean Mantra:
 
A place for everything and everything in its place.
 
***
Set in Order (Seiton) is the second 'S' in the 5S Methodology.
 
It's about organizing your work area so that everything has a designed place.
 
Set in Order seems simple in theory,
but total commitment is key during execution.
 
Seiton requires analysis on:
 
-workflow
-storage need
-safety concerns
-used tools/materials
 
Top Tip to Set in Order:
 
Install Shadow Boards
 
(A PRO level one in the video below)
 
When you set it in order, you ensure all items left
in the work area are organized.
 
Each item should be easy to find, use, and return
in line with the physical workflow.
 
Your operators will be able to immediately see
if things are out of place and put them back into order promptly.
 

via Andrej Morocz

***
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AI won't replace humans.
 
But humans with AI will replace humans without AI.
 
And it will make your Zero Defect strategy obsolete.
 
Zero Defects is a quality management philosophy 
aimed at eliminating defects in production processes. 
 
This way of thinking (and doing)
reinforces one simple notion:
 
Defects aren't acceptable.
Do things right the first time.
 
Core principles:
 
1/ Prevention Focus
 ↳ Focus on preventing defects
 ↳ Prevention > Inspection
 
2/ Right First Time
 ↳ Avoid rework and waste
 
3/ Change Attitudes
 ↳ Shift your organizational culture
 ↳ Build zero-error systems
 
3/ Employee Involvement
 ↳ Engage all employees in the quality improvement process
 
4/ Cost of quality
 ↳ 1-10-100 Rule is real stuff
 ↳ Preventing defects is less expensive than fixing them later
 
AI-powered object recognition can
 
+count items in real-time
+check quality with precision
+reduce downtime and waste
 
while enhancing your Zero Defects strategy.

***
Do you want to apply a similar solution in your business? 

Click here: https://lnkd.in/dZVDk4sE

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