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 posts about Lean, Continuous Improvement & Personal Development | CI Manager @ Amazon

Hello stranger! 👋 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

Modular Innovation 
 
Level: PRO 
 
*** 
Modularization is the process of dividing a complex system into smaller, more manageable parts. 
 
It's a critical approach for: 
 
+driving innovation 
+increasing competitiveness 
+connecting with mass customization 
+balancing standardization and customization 
 
It makes adding, modifying, or replacing components easier without compromising the overall system integrity.  
 
Modularization balances 3 basic drivers: 
 
	1. Create variety 
	2. Utilize similarities 
	3. Reduce complexity 
 
This principle can empower your company to innovate rapidly, adapt to changing market demands, and optimize resource utilization. 
 
It's a way to simplify product design, manufacturing, service, and spare part deliveries. 
 
The beauty of simplicity.  
*** 
 
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Video Credit: Amir Sanatkar

Ivan Carillo

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

Poka-Yoke in Digital Manufacturing? 
 
Yes, you can! 
 
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. 
 
Digital Poka-Yoke can add value to your workstations through: 
 
+digital storage and distribution of new procedures 
+guidance for your operators with projected AR 
+easier onboarding of new workers 
+elimination of paper manuals 
+enhanced quality control 
+flexible production 
 
Visual aids support operators in making the right judgement call. 
 
*** 
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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.

***
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No need for disruption.  
 
1% better. Every day.  
 
Kaizen is the way.

Do you want to improve your dock operations?

Merge ATLS with SMED methodology!

Automatic Truck Loading System (ATLS) is a top solution to automate the reception and delivery area in your warehouse.

Automatic, one-off loading/unloading of trucks is the first step to full warehouse efficiency.

Key benefits:

+Automated load management
+No customization of truck trailers
+Reduced capital and operating costs
+Less dock doors needed (5x reduction)
+Automatic loading/unloading of 33 pallets
+Efficient control of loading/unloading activities
+Accident prevention and reduced risk of damages
+Full system integration with conveyor, AGV, and so on

ATLS is a comprehensive system consisting of elements that enable handling various loads - depending on your operational needs. 

It's an application of SMED methodology for process optimization.

The essence is to convert as many changeover steps as possible to “external” and to simplify the remaining ones.

***
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Digitalizing 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.  
  
Digital Poka-Yoke can add value to your workstations through:  
  
+digital storage and distribution of new procedures  
+guidance for your operators with projected AR  
+easier onboarding of new workers  
+elimination of paper manuals  
+enhanced quality control  
+flexible production  
  
Visual aids support operators in making the right judgement call.  
  
***  
P.S. If you enjoyed this, repost it for your network and follow me Ivan Carillo for more.

VSM isn't just a Lean tool. 
 
It's the key to your business success. 
 
The main goal of a business is to provide outstanding value at the lowest price. 
 
In line with this goal, Value Stream Mapping aims to show you where you can reduce waste. 
 
VSM visualises your operations from material inputs to customer delivery. 
 
Here are 5 simple steps to create your Value Stream Map: 
 
Step 1. Pick a Product Family 
 
Recognize the value stream from your customer perspective. 
 
Select a large-quantity and high-revenue product family. 
Focus on reducing cycle times for your best sellers. 
 
It's crucial to maximize the gains. 
__ 
 
Step 2. Build your team 
 
Assign a dedicated team leader. 
Pick subject matter experts from key departments. 
 
Make sure they know enough about the product and VSM. 
__ 
 
Step 3. Figure out your customer demand 
 
Check your production history. 
 
Figuring out your customer demand is critical to calculate your takt times. 
__ 
 
Step 4. Map the material flow 
 
Map the journey that materials embark on, from receive to customer delivery. 
 
It helps identify waste by analyzing each step of material handling. 
 
Look at how the material flow is secured by operators. 
 
At this point, key questions can be: 
 
-What systems are in place to replenish your inventory levels? 
 
-Do your operators have the materials they need to hand? 
 
 
Then, add the collected data to this flow. 
__ 
 
Step 5. Map the information flow 
 
How does information move through the value stream from the initial request to order delivery? 
 
Capture how the information (e.g. feedback) goes through your organization. 
 
Pinpoint communication gaps, and enhance data flow. 
__ 
 
TL;TR 
 
5-step framework for Value Stream Mapping: 
 
1. Pick a product family 
2. Build the VSM team 
3. Figure out your customer demand 
4. Map the material flow 
5. Map the information flow 
__ 
 
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Highly motivated and hard-working engineer with a comprehensive understanding of Lean Six Sigma and Operations Management methods. Dynamic and outgoing, I have an analytical mindset and a natural ability to effectively interact with all staff levels. 

Feel free to reach out to me at carillo.iv@gmail.com

Muhammad Faizan

Single Minute Exchange of Die (SMED) 
 
Level: PRO 
 
SMED is a lean production method for reducing inefficiencies in a process. 
 
It provides a rapid way of switching your production from product A to product B. 
 
The ultimate goal is to reduce the changeover time from hours down to < 10 mins. 
 
Key benefits: 
 
+Smaller lot sizes 
+Greater flexibility 
+Lower operative costs 
+Lower skills requirements 
+Reduced uneven flow (Mura) 
+Increased machine work rates 
+Standardized changeover procedures 
+Better responsiveness to customer demand 
 
__ 
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Manufacturing processes are often plagued by inefficiency. 
 
Here's why:  
 
Manufacturers cling to old batch habits. 
___ 
 
Batch Production is a traditional manufacturing method where identical or similar items are produced in batches, before moving on the next step. 
 
Some manufacturers argue large batches balance workloads and minimize changeovers. 
 
But data often shows otherwise. 
 
Overlong production runs cause overproduction. Operators lose focus working on large batches, while equipment drifts out of standards between changeovers. 
 
Main drawbacks: 
 
-Piles of WIP inventory waiting for the next step 
-Defects hide among the batches 
-Inefficient space management 
-Uneven workflow 
-Long lead times 
 
Those lead to: 
 
-Some stations being overloaded, others waiting 
-Low responsiveness to customer demand 
-More scrap and rework 
-Higher carrying costs 
-Facility costs up 
 
Switching to One-Piece Flow can bring relief.   
 
Workstations are arranged so products can flow one at a time through each process step. Changeovers become quick and routine. 
 
Main advantages: 
 
+High customer responsiveness 
+Minimal work-in-process inventory 
+Quality issues are detected immediately 
+Reduced wasted space and material handling 
+Easy to level load production to match takt time 
 
The selection between batch processing and one-piece flow can significantly impact quality, productivity, and lead time in a manufacturing process. 
 
P.S. Some case studies show labour productivity improvements of 50% or more. Lead times can drop by 80%. And quality can approach Six Sigma.

95% of the time is wasted in a traditional business.

Only the remaining time is for the actual work.

Modern organizations need less of: 

→ Traditional thinking
→ Complexity as the norm
→ Dynamic schedule & priorities
→ Specialized, one-function people
→ Unclear accountability & ownership
→ Endless reviews, inspections and approvals
→ Rewards for problem-solving (putting out fires)

But more of: 

→ Rewards for problem detection (prevent the fires)
→ Decisions made by those closest to the work
→ Cross-trained and versatile employees
→ Clear accountability & ownership
→ Static priorities & schedule
→ Overcoming complexity
→ Lean thinking

Conventional product launches may take months.

Lean Thinking can make a launch happen within a few weeks. 

That's not magic.
It’s the power of value-driven, flexible systems. 

Lean managers promote fast root-cause troubleshooting, comprehensive monitoring and two-way door decision-making. 

If you don't like change, you'll like irrelevance even less.

You must create value for the customer at the heart of your enterprise. 

***
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How to build your critical thinking skills in 7 simple steps:

Critical Thinking

5 Lean principles every leader should know:

5 Lean Principles

How to implement poka-yoke solutions in 6 simple steps:

Poka Yoke Implementation

"Slow is smooth. Smooth is fast"

SMED can play a pivotal role, not only in F1 pit stops.

Single-Minute Exchange of Die is a system for reducing the time to complete equipment changeovers.

So, the ultimate goal is to reduce the changeover time from hours down to < 10 minutes (much less for the F1 case)

From 1990 to 2023, F1 pit stop times dropped significantly through Standard Work, Lean, and Innovation.

Watch this video to learn the importance of accuracy and consistency in executing critical tasks!

***
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First Time CI Manager

'Alright, alright, alright!' 
 
First words Matthew McConaughey ever said on film. 
 
And it was off-screen if you watch 'Dazed and Confused'. 
 
It's incredible how that line stuck. 
 
Since then, he built the man, the myth, the legend. 
 
And his speech from the 2014 Oscars is just amazing. 
 
It's about the hero he is chasing. 
 
He says: 
 
'I am never going to be my hero, and that's just fine' 
 
This reminds me of a concept that I feel connected to. 
 
Utopia. 
 
I love the quote by Eduardo Galeano about: 
 
“She is on the horizon. 
  
I go two steps; she moves two steps away.  
I walk ten steps and the horizon runs ten steps ahead.  
 
No matter how much I walk, I'll never reach her.  
 
So what good is Utopia?  
 
That's what:  
She is good to keep walking.” 
 
You'll probably never be your hero, but keep on chasing.

Clever Store Shelves 
                 ↳ FIFO Masterpiece 
 
FIFO (First In, First Out) is a powerful concept in manufacturing and supply chain management.  
 
It's a simple yet effective inventory management technique. 
 
Understanding FIFO: 
 
The oldest materials, products, or items should be used or sold first before the newer ones. 
 
In this way, items don't remain in storage for extended periods. 
 
Key Benefits: 
 
+Relevant cost savings  
+Workflow optimization 
+Optimal inventory levels 
+Consistent product quality 
+Higher customer satisfaction 
+Reduced risk of obsolescence 
 
By embracing the FIFO concept, companies can enhance their operations, reduce waste, and foster a CI culture. 
 
Benefits of FIFO merchandising systems: 
 
+Increased sales 
+Quick ROI (<1 year) 
+Lower refilling times (≃70%) 
+More sustainable business model 
+ Reduced waste caused by expired products 
 
*** 
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Fear of failure is a creativity killer. 
 
Creative thinkers need freedom to flourish.  
 
Do you want to drive innovation in your workplace? 
 
Build a blameless work culture first. 
 
Mistakes must be normalized as human. 
They must be accepted, and used as learning opportunities. 
 
Get comfortable taking more risks. 
 
If you never fail a challenge, you're probably not aiming at high-value targets.  
 
Failure is your key to success.

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