A Flexpipe roller track is an essential component for lean gravity-fed FIFO (First-In, First-Out) flow racks. They are used in material-handling systems, such as picking and kitting carts and racks, and line-side replenishment, where material storage and retrieval must be seamless. A roller track consists of low-friction rollers securely mounted within a steel frame. Accessories … Continued

Every journey starts somewhere. In lean manufacturing, that journey begins with a continuous improvement (CI) workshop. A CI workshop provides the foundation by which your company can make significant lean improvements that reduce waste, increase throughput, and reduce costs. When Flexpipe customers want to learn the most efficient, proven ways to run a successful CI … Continued

Kaizen is a continuous improvement methodology incorporating multiple practical applications like 5S, value-stream mapping, fishbone diagrams, spaghetti diagrams, Pareto charts, control charts, and the Shewhart PDCA (Plan, Do, Check, Act) cycle. However, at its core, Kaizen is ultimately about fostering an environment where employees and management are motivated to improve where they work, how they … Continued

Flexpipe embarks on a digital lean transformation, implementing just-in-time and “5-zero” principles to enhance operational efficiency and manufacturing sustainability. Cumbersome bureaucratic procedures are now a thing of the past for Flexpipe. Initiating a digital shift in 2019 regarding the digitization of all administrative documents, the company has now moved on to digitizing assembly drawings, marking … Continued

Lean manufacturing isn’t just about cutting costs — it’s a philosophy of continuous improvement and strategic planning that transforms the entire production process. Among the many lean tools, Hoshin Kanri stands out as a methodical approach to aligning company goals with practical, on-the-ground operations. This guide explores how manufacturing engineers can apply Hoshin Kanri to … Continued

In the manufacturing realm, optimizing for efficiency while meeting ever-evolving market demands is critical. Enter Heijunka, a Japanese technique of “leveling production”. Renowned as the backbone of the Toyota Production System (TPS) and the foundation of Lean methodology, Heijunka serves as a beacon for operational excellence. Understanding Heijunka Heijunka, pronounced “hey-june-kuh”, is more than just … Continued

The aerospace industry relies upon a worldwide interconnected supply chain where time-critical and essential raw materials, machined parts, and integrated assemblies must be delivered on time and in good working order. Lean environments abound, and suppliers on multiple continents must focus on eliminating waste and reducing lead times while guaranteeing the highest quality of finished products. 

In lean manufacturing and continuous improvement environments, the Gemba Walk is the all-important first step to starting the day. It aligns expectations, what work must be completed, reviews work processes, and empowers managers and employees to identify potential waste and improvements. Manufacturers use the Gemba Walk daily to improve operations and reinforce a continuous improvement mindset.

When companies think about Kanban, the image of a Kanban board and Kanban cue cards often come to mind. This simple lean manufacturing scheduling system summarizes workflow on a board, showing individual steps required to complete a given project, work, or operation. The Kanban board is the repository for the Kanban cards. The board outlines … Continued

5S, a continuous improvement methodology widely recognized as a building block of lean manufacturing. 5S spearheaded the rise of just-in-time (JIT), a supply chain management and lean manufacturing process that minimizes waste while maximizing efficiencies.