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Slimming down

By Gary Forger, Editorial Director -- Modern Materials Handling, 9/1/2005

Even though beach season in the Northeast has pretty much come and gone, that doesn't mean we're past the time for slimming down. In fact, if you look at two particular stories in this issue, you'll see that lean is definitely a bonus during any season.

Start with Roberto Michel's report on lean manufacturing (Learn from lean's best). It's based on a report from the research firm Aberdeen Group. By talking to leaders in lean manufacturing, it's clear that the success of these programs "depends on the integration of tactics and techniques with a culture that advocates lean both within and outside the four walls."

This is interesting in a couple of different ways. To begin, lean manufacturing has traditionally placed a greater emphasis on techniques than culture. But according to this report, the two are at least co-partners with culture sometimes having an upper hand. Or to put it in swimsuit diet terms, it's as much about how you think about eating as it is what you eat.

Going outside the four walls is also noteworthy. Aberdeen says the more advanced lean manufacturers are reaching out to suppliers and customers alike. They are focused on transforming all of the nodes of their supply chains from push to pull and putting all on the lean diet. Imagine a beach filled only with people who neatly fit in their bathing suits.

If you take a look at the page opposite the inside back cover, you'll see that lean is the focus there too. Except this one has nothing to do with manufacturing. The story here is what RadioShack is doing with lean warehousing. Yes, lean warehousing.

As Phil Godden of RadioShack explains, there's so little written or even known about lean warehousing, that this is a bit of a pioneer effort. Nonetheless, it does fit right into the push by lean manufacturing leaders to extend the practice across the supply chain.

And as it turns out, lean warehousing, like lean manufacturing, has a strong culture component too. In fact, Godden says that this effort was in part intended to make continuous improvement a part of the warehouse culture. Which is exactly what's happening at the company's six DCs. Or in swimsuit terms, it's much better to be slim the year 'round, than just May through September.

Think of lean that way and you've got an endless summer theme going. But that's a whole other discussion that will have to wait for another day.

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