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• Who is Casey Bralla?

Lean Topics

• Lean Overview
• Is Lean a Fad?
• Lean is...
• The 7 Deadly Wastes
• Visual Metrics
• Day-by-the-Hour Boards
• Visual Factory
• Kaizen Blitz
• Gemba Walk
• Lean Assessments
• 6-Sigma
• Lean vs. 6-Sigma
• Lean Success Stories
• Why Lean Fails

Vocabulary

• Lean Vocabulary Overview
• 5S
• 6-Sigma
• 7 Deadly Wastes
• Andon Cord
• Andon Light
• Autonomation
• Black Belt
• Buffer Stock
• Changeover Time
• Charter (Project Charter)
• Cycle Time
• Day-by-the-Hour (Pitch)
• DMAIC
• First Pass Yield
• Gemba
• Gemba Walk
• Green Belt
• Heijunka Box
• Herbie
• Hoshin Kanri
• Kaizen Blitz
• Kan Ban
• Lean Six Sigma (LSS)
• Line Balancing
• Master Black Belt
• Muda
• Overall Equipment Effectiveness (OEE)
• Pitch (Day-by-the-Hour)
• Poke Yoke
• Policy Function Deployment
• Pull System
• Red Tag System
• Safety Stock
• SMED
• Supermarket
• Takt Time
• Value (added & Non-added)
• Visual Factory
• Visual Metrics
• What Does Good Look Like (WDGLL)

Reading

• Essays
• The Goal
• Lean Thinking
• Design for Manufacturability
• Handbook of Manufacturing Processes
• DFX: Design for Excellence

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Entire site Copyright © 2012 by J. R. Casey Bralla
(except for obvious external works).
All rights reserved.

NOTE: If you link to this site, or otherwise find it useful, please send a brief note to the author. Thank you!

Who is Casey Bralla?

I am an energetic, seasoned engineering executive with over 40 years experience as a Lean Champion, Engineering Manager, Plant Manager, Quality Manager, Continuous Improvement Manager, Manufacturing Engineer, and QUALITY Engineer working with industrial, automotive, and consumer products.

I have direct experience in:

• Direct Labor efficiency improvements utilizing Lean Manufacturing and 5S principles
• Inventory and WIP reductions utilizing Kan Ban
• Scrap & Defect reduction utilizing Standard Work procedures and Poke Yoke devices
• 5S and Lean Manufacturing implementation
• Kaizen Blitz implementation.
• ISO/TS-16949 manufacturing systems.
• ISO 9001:2015 manufacturing systems.
• Multi-million dollar capital project management.
• Customer Complaint Corrective/Preventative actions CAPA).
• Ergonomic analysis and improvement.
• Machining, Metal forming, Molding, Painting, custom equipment building, and Assembly operations.
• Custom equipment design and installation.

I have personally introduced Lean Manufacturing to industrial companies and been responsible for changing plant cultures that were based on "tribal knowledge", and transformed them into organizations that value Standard Work, and are data-driven.

I am a published author, with articles explaining the basic structure of CNC Machine Tools in McGraw-Hill's Encyclopedia of Science and Technology, and a chapter on Plastics Extrusion for McGraw-Hill's Design for Manufacturability Handbook

I publish a blog about Technology, my projects, and my philosophical musings at The NerdWorld Report.

I also am a computer nerd, hosting my own servers for my (unfortunately) not-with-profit internet business.

I am retired and very happy to offer free advice via phone or eMail. If you live in the Philadelphia, PA or northern Delaware area, I would even be happy to come see your facility and offer my advice, (I love finding any excuse to tour a factory; I learn something every time!) Call or eMail me, and we can discuss any needs you have.

Call me at 610-810-7716

or eMail at

(Click the address above to open your eMail program.)

You can also contact me via my Linkedin account.