Latest news with #Lean
Edinburgh Reporter
20 hours ago
- Business
- Edinburgh Reporter
How Reducing Waste in Manufacturing Starts with Accurate Counting and Sorting
Imagine this. You're running a mid-sized manufacturing facility. Orders are up, machines are running, and your team is pushing to meet deadlines. Yet, by month's end, inventory discrepancies spike, material waste piles up, and your bottom line takes a hit. Sound familiar? What if the root of this waste isn't poor planning or employee error—but something deceptively simple: inaccurate counting and inefficient sorting? Image from / Annie Spratt In today's hyper-competitive manufacturing landscape, reducing waste isn't just about sustainability; it's about survival. Every piece of misplaced inventory, every batch of miscounted components, and every poorly sorted item translates into lost time, wasted resources, and lower profitability. And in many cases, the solution starts not with expensive machinery upgrades or sweeping process overhauls—but with sharper precision at the very first step of production: precision counting and sorting. In this article, we'll uncover why these basic operations are more powerful than they appear, how companies are leveraging modern solutions to reduce manufacturing waste dramatically, and what practical steps you can take—starting today—to tighten control, cut costs, and boost operational efficiency. Because in manufacturing, the smallest miscounts can lead to the biggest losses. Why Counting and Sorting Are the Hidden Gatekeepers of Waste Reduction When we talk about waste in manufacturing, conversations often leap to buzzwords like automation, lean systems, or just-in-time inventory. But before any of those advanced strategies can work, there's a quieter force at play: how accurately your materials are counted and how efficiently they're sorted at the start of your production line. The Domino Effect of Inaccuracy Let's break it down. Suppose a batch of screws is miscounted at the inventory intake stage—off by just 5%. That may seem trivial, but here's what can happen: Production delays : Assemblies halt when you're short, even if just a few pieces are missing. : Assemblies halt when you're short, even if just a few pieces are missing. Overordering : Teams may compensate by ordering more than necessary 'just in case,' leading to excess inventory. : Teams may compensate by ordering more than necessary 'just in case,' leading to excess inventory. Scrap and rework: Inaccurately sorted components may end up in the wrong product runs, increasing defective outputs. Each small error compounds through the system, creating what Lean manufacturing experts call 'invisible waste.' And once it infiltrates the workflow, it's incredibly costly to undo. Real-World Example: Automotive Supplier Cuts Waste by 27% A Tier 2 automotive parts supplier in Michigan faced rising material costs and quality complaints. Their root cause analysis didn't reveal machine issues—it uncovered a flawed manual counting system during inbound part verification. By integrating automated vision-based counters and RFID sorting, the company: Reduced manual counting errors by 92% Decreased material waste by 27% in 6 months Improved on-time delivery by 18% The fix wasn't flashy. It was foundational. And it worked. Why Traditional Methods Fail Relying on manual labor or basic checklists might seem cost-effective in the short term. But human error is inevitable—especially in high-volume, repetitive environments. Fatigue, distraction, and assumptions lead to inconsistent data, and that flawed data becomes the backbone of every subsequent decision. Here's what often goes wrong: Employees count by weight or volume, assuming uniformity in parts. Components are mislabeled or placed in the wrong bins. Sorting is rushed to meet quotas, leading to misclassification. The result? Misalignments that ripple across departments—from procurement to quality assurance. The Psychology of Precision: Why Small Errors Multiply in Manufacturing Systems At first glance, the idea that a few miscounted parts or poorly sorted items could cripple an entire production process might seem like an exaggeration. But manufacturing, by its nature, is a tightly interwoven system. Each step relies entirely on the accuracy of the previous one. There's no margin for small errors—because they don't stay small for long. Let's look at this through a systems-thinking lens. In a typical production line, especially in sectors like electronics, automotive, or packaging, the number of components required can easily run into the thousands per day. If just 1% of those are incorrectly counted or sorted, you're dealing with dozens—if not hundreds—of inconsistencies every single shift. Over the course of a month, that's enough to derail schedules, inflate costs, and erode client trust. What makes the issue more dangerous is that these small discrepancies often remain undetected until much later in the process. A miscounted input might not trigger an alarm until it results in a missing part during assembly—or worse, a product recall after delivery. By then, the cost of rectifying the problem has already multiplied exponentially. Consider the hidden emotional toll within the workforce, too. Line workers and operators, already under pressure to meet deadlines, face increased scrutiny and blame for failures that originate upstream. Morale suffers, blame loops form, and what was once a technical glitch becomes a human issue—affecting teamwork, communication, and trust. What's often overlooked is that counting and sorting aren't just administrative or logistical tasks—they're trust points. When those numbers are off, confidence in the entire process begins to erode. Image from / Mika Baumeister Modern solutions like vision recognition systems, machine learning–driven counters, and automated sorters don't just offer speed. They offer consistency. They become impartial arbiters of truth on the shop floor—removing ambiguity and giving managers reliable data to act on. But the shift is not just technical; it's cultural. Moving from manual to automated accuracy requires buy-in, retraining, and a mindset shift about what precision truly means in today's manufacturing environment. And that shift, while difficult, is essential—because in high-stakes production, precision isn't a luxury. It's the standard. Technology as the Enabler — But Not the Full Solution It's tempting to believe that once you integrate automation, the waste problem is solved. Barcode scanners, AI-driven sorters, smart bins—there's a growing market of tools promising zero-defect production through better tracking and counting. And yes, these tools are powerful. But without a strategy, without process alignment, and without human accountability, they can quickly become expensive band-aids rather than real solutions. Technology amplifies precision—but it doesn't create it on its own. Let's return to our earlier example of the automotive supplier. Their mistake wasn't that they lacked tech. They had scanners, spreadsheets, and tracking systems in place. Their mistake was depending on inconsistent human inputs feeding into automated systems. What they learned—and what many manufacturers eventually come to realize—is that automation without standardization is chaos at scale. Smart factories are not just about machines talking to each other. They're about people and processes integrating with technology in a way that preserves clarity and reduces interpretation. That requires leadership. Before a single machine is upgraded, manufacturers must evaluate: Are our counting protocols standardized across shifts and teams? Is our sorting logic intuitive and consistent with our BOMs and SKUs? Are we training staff not just in equipment usage, but in why accuracy matters? What's fascinating is that some of the most effective changes begin with something as simple as redefining roles. In facilities where warehouse teams feel accountable for count accuracy—not just data entry—the rate of downstream errors drops significantly. When quality control teams are empowered to audit not just final products, but early-stage sorting bins, they often detect flaws days before they become defects. In this sense, reducing waste becomes less about investing in high-end robotics and more about building a culture of precision, supported by the right tools. So yes, counting and automated sorting can—and should—be enhanced by technology. But those tools must sit within a framework of human responsibility, smart process design, and constant iteration. Otherwise, you're simply accelerating the rate at which errors travel through your system. Final Thought? Waste Reduction Begins Where You Least Expect It In manufacturing, we're trained to chase the big fixes—automating production lines, streamlining logistics, cutting supplier costs. But the truth is, many of the biggest gains come from areas we often overlook. Counting. Sorting. Precision at the source. These aren't glamorous parts of your operation. They don't make headlines in trade journals. But they are the foundation of everything that follows. And when they're done right, they silently drive quality, efficiency, and profit. If you're serious about reducing waste—not just environmentally, but operationally and financially—you need to start where the process starts. Audit how your materials are counted. Walk your sorting lines. Ask your teams what tools they need to do it better. Then commit to the upgrades—whether in systems, training, or precision counting equipment—that turn accuracy into a competitive advantage. The best time to fix your precision problems was yesterday. The second-best time is now. Don't wait until waste eats into your margin. Act today—recalibrate your frontline processes and build a manufacturing line that counts what matters. Like this: Like Related
Tom's Guide
22-05-2025
- Health
- Tom's Guide
All you need is 5 minutes to build core strength and stability, according to a certified Pilates instructor
If you're looking to build a strong and stable core, we've got good news — according to a certified Pilates instructor, you don't need to spend hours in the gym doing planks and sit-ups. You only need five minutes and the right exercises. The workout below, designed by Pilates instructor and Lean app founder Lilly Sabri, uses slow and controlled movements to keep your core engaged. The workout focuses on deep core activation to help you strengthen and sculpt your abdominal muscles and deep stabilizer muscles. Ready to give it a go? Read on to find out more. The workout features some key Pilates exercises that focus on the deep core. You'll do each for 45 seconds, followed by a 10 second break. There's only five exercises in total, and you won't need any extra equipment. That said, you might want to use one of the best yoga mats to lie on. Here's the exercises: All of these classic Pilates core exercises focus on the deep abdominal muscles, used to stabilize and support the midsection as you move. Strengthening these muscles can help improve your posture and protect you from lower back pain. Pilates can also improve your flexibility and stability, essential, whatever you're training for. Get instant access to breaking news, the hottest reviews, great deals and helpful tips. This workout probably won't leave you feeling exhausted or like you've worked up a serious sweat, but Pilates is all about small, controlled, precise movements to target your core. This low-impact workout is suitable for all levels, as Lilly offers modifications for beginners, and the slower you move, the better. If sculpting visible abs is your goal, regular Pilates practice can help tighten and tone your midsection. You'll want to pair your Pilates practice with good nutrition, cardio, and strength training. Whatever your goal, the slow, controlled movements will help build strength and endurance, without the impact of running or jumping.
New York Post
21-05-2025
- New York Post
Texas student-teacher who allegedly had sex with teen told cops she saw him as ‘a little brother'
A Texas high school student teacher who admitted to having sex with a teen boy she taught told cops she saw him 'as a little brother,' authorities said. Darian Christine Rogers, 22, has been charged with second-degree felony improper relationship between an educator and a student, arrest records show. She first met the boy at a grocery store where the pair worked at the time, before she became a student teacher at Rouse High School in Leander, a suburb north of Austin, FOX 7 reports. Advertisement Rogers, who has been working at the high school since January this year, was reported to authorities in April by a student who said she had 'personal knowledge' of a teacher being involved in a sexual relationship with a minor, court paperwork seen by the local outlet states. 7 Texas student teacher Darian Christine Rogers, 22, told police she saw her victim as a 'little brother.' Williamson County Jail The student also provided a voicemail from a woman — identified as Rogers by Williamson County Sheriff's Office — in which she admitted to sending explicit photos to a 17-year-old male. Advertisement Her alleged victim initially denied the illicit relationship to police until he was confronted with messages detectives found on his phone between him and Rogers discussing the Plan B contraceptive pill, FOX 7 reported. Rogers denied having sex with the boy in her police interview and described their relationship as that of a 'big sister and little brother,' according to the affidavit. 7 Rogers started working as a student teacher in January this year. Instagram / Darian Rogers She then admitted to having sex with the student 'one time' in his truck in a parking lot near the H-E-B grocery store where they both worked after she was confronted with the text evidence, the affidavit states. Advertisement 7 Rogers also confessed to an illicit relationship with another student. Facebook / Darian Rogers Rogers warned the student to avoid 'inappropriate comments' in front of school staff as she was interviewing for a position there, the affidavit states. 7 The illicit relationship happened before Rogers started working as a student teacher at Rouse High School in Leander, Texas. Google Maps A video of Rogers taking the Plan B pill and a screenshot of the receipt were also found on her phone by detectives. Advertisement 7 Rogers had sex with the underage boy when the pair worked at an H-E-B grocery store. LinkedIn / Darian Rogers Another text thread between Rogers and a friend described a previous sexual relationship between her and a different child who was 17 and a student in the Leander Independent School District at the time. 7 The school's principal sent a letter to students' families after Rogers' arrest. Google Maps The school's principal sent a letter to the families of students on Friday following Rogers' arrest. 7 Rogers confessed to having sex with the boy in his truck outside the H-E-B where they worked together. Google Maps 'The individual was not a Leander ISD or Rouse High School employee and was immediately removed from campus once the district was made aware of the situation,' the letter from Rouse High School principal Vincent Hawkins and seen by FOX 7 reads. 'Any accusations of misconduct did not happen on our campus, during school hours, or at any school-sponsored event,' the letter continues. Advertisement Rogers was booked into Williamson County Jail on Friday and released the following day on a $20,000 bond. She is next due in court on June 4 for a pre-indictment docket call, arrest records show.
The Sun
21-05-2025
- Entertainment
- The Sun
I found out my fiancé was a cheat when gossiping podcasters exposed him – they never said sorry for devastating my life
It was just another ordinary November morning for Lilly Sabri… until she looked at her phone. The fitness influencer was bombarded with messages (she estimates in the thousands) from friends, family and strangers, all letting her know that her fiancé had cheated on his stag do. 2 The 35-year-old, who boasts over six million YouTube subscribers and founded a million-pound health company named Lean, was accustomed to receiving thousands of direct messages daily about her Pilates workouts and healthy recipes. But November 9 in 2023 was completely different. While she was sleeping, a popular podcast released a new episode about a man who supposedly cheated on his well-known fiancé. The hosts of The Girls Bathroom, Sophia Tuxford and Cinzia Baylis Zullo, allegedly dropped enough hints to suggest that it was Lilly's relationship they were talking about. They discussed the couple's dog, their home in Dubai, their recent engagement and even alluded to Lilly's business ventures. With the podcast attracting millions of listeners per episode, speculation about the couple's identity spread like wildfire across social media. 'I didn't know what had happened,' Lilly told the Mail. 'I opened Instagram, and there were thousands and thousands of messages with a link to a podcast. 'People were alluding that something had happened, but I had to hear it for myself. 'Everything I knew and trusted felt like it had exploded. 'I was in disbelief. It felt like I was in a reality TV show, but it was my own life, and I had zero control over it. I hadn't asked for this.' The physiotherapist-turned-influencer watched the episode 10 times that day, trying to process the shocking news. Two weeks later, after widespread speculation about her relationship, Lilly released a statement confirming the rumours were true - Sophia and Cinzia had indeed been discussing her fiancé. She wrote on Instagram: 'On Thursday 9th November, I woke up to messages about a podcast episode discussing a relationship involving a newly engaged man, meeting a woman on his stag do, and subsequent encounters. 'It's heartbreaking to confirm this is true, and discovering it in this way has been devastating.' Four red flags your partner is cheating Private Investigator Aaron Bond from BondRees revealed four warning signs your partner might be cheating. They start to take their phone everywhere with them In close relationships, it's normal to know each other's passwords and use each other's phones, if their phone habits change then they may be hiding something. Aaron says: "If your partner starts changing their passwords, starts taking their phone everywhere with them, even around the house or they become defensive when you ask to use their phone it could be a sign of them not being faithful." "You should also look at how they place their phone down when not in use. If they face the phone with the screen facing down, then they could be hiding something." They start telling you less about their day When partners cheat they can start to avoid you, this could be down to them feeling guilty or because it makes it easier for them to lie to you. "If you feel like your partner has suddenly begun to avoid you and they don't want to do things with you any more or they stop telling you about their day then this is another red flag." "Partners often avoid their spouses or tell them less about their day because cheating can be tough, remembering all of your lies is impossible and it's an easy way to get caught out," says Aaron. Their libido changes Your partner's libido can change for a range of reasons so it may not be a sure sign of cheating but it can be a red flag according to Aaron. Aaron says: "Cheaters often have less sex at home because they are cheating, but on occasions, they may also have more sex at home, this is because they feel guilty and use this increase in sex to hide their cheating. You may also find that your partner will start to introduce new things into your sex life that weren't there before." They become negative towards you Cheaters know that cheating is wrong and to them, it will feel good, this can cause tension and anxiety within themselves which they will need to justify. "To get rid of the tension they feel inside they will try to convince themselves that you are the problem and they will become critical of you out of nowhere. Maybe you haven't walked the dog that day, put the dishes away or read a book to your children before bedtime. A small problem like this can now feel like a big deal and if you experience this your partner could be cheating," warns Aaron. In the aftermath, Lilly took a hiatus from social media, despite building her entire career online and posting multiple times a day. 'I just wanted to disappear. I couldn't get away from it,' she recalled. 'I literally couldn't look in the mirror for about nine months afterwards because I was picking myself apart. 'What happened affected my family too. 'Millions of people found out about my personal life before I did. 'It's humiliating. It was so humiliating for me.' After posting the statement, Lilly checked her social media to see if the podcast hosts had reached out to apologise, but they never did. A year and a half later, she still hasn't 'heard anything' from them. The emotional toll of the experience meant Lilly's physical and mental health took a significant hit, and she's had to pull herself out of some 'dark places' over the last 18 months. I was in disbelief. It felt like I was in a reality TV show, but it was my own life, and I had zero control over it. I hadn't asked for this Lilly Sabri 'It's obviously been a long time, a difficult time, but through that period, I've learned a lot, and I feel like I'm in a good place now,' she said. 'Mentally, I wasn't in a place to show up on social media, and that eventually affected my physical health as well. I needed to prioritise my mental health. 'If you'd asked me a year ago, I wouldn't have said I'd be able to do this right now. 'But finally, I feel ready.' Mentally, I wasn't in a place to show up on social media, and that eventually affected my physical health as well. I needed to prioritise my mental health Lilly Sabri Lilly, a qualified physiotherapist and Pilates instructor, has an impressive CV that includes the NHS and Watford Football Club, before she fully transitioned to social media. In 2021, she brought her 'Lean' method to the forefront with the launch of a fitness app and a range of nutritional products under the same name. Today, Lilly is the sole shareholder of her health brand, Lean, and she plans to integrate the mental health strategies she's learned into the business going forward. 'Without everything that happened, I wouldn't be here right now,' she said. 'I wouldn't have gotten through it. I can't tell you how much it saved me. 'This is a huge part of my new purpose. It's wellness, it's mental health, it's helping people. 'Whether it's a mental health crisis, anxiety, depression, or simply feeling overwhelmed, I want to help people with the skills I've learned, all while doing it with kindness.'
The Irish Sun
21-05-2025
- Entertainment
- The Irish Sun
I found out my fiancé was a cheat when gossiping podcasters exposed him – they never said sorry for devastating my life
It was just another ordinary November morning for Lilly Sabri… until she looked at her phone. The fitness influencer was bombarded with messages (she estimates in the thousands) from friends, family and strangers, all letting her know that her fiancé had cheated on his stag do. 2 Lilly found out that her fiancé had cheated on his stag do through a podcast Credit: Instagram 2 The fitness influencer took a social media hiatus and has spent the last 18 months rebuilding her life Credit: Instagram The 35-year-old, who boasts over six million YouTube subscribers and founded a million-pound health company named Lean, was accustomed to receiving thousands of direct messages daily about her Pilates workouts and healthy recipes. But November 9 in 2023 was completely different. While she was sleeping, a popular podcast released a new episode about a man who supposedly cheated on his well-known fiancé. The hosts of The Girls Bathroom, Sophia Tuxford and Cinzia Baylis Zullo, allegedly dropped enough hints to suggest that it was Lilly's relationship they were talking about. read more real life They discussed the couple's dog, their home in Dubai, their recent engagement and even alluded to Lilly's business ventures. With the podcast attracting millions of listeners per episode, speculation about the couple's identity spread like wildfire across social media. 'I didn't know what had happened,' Lilly told the 'People were alluding that something had happened, but I had to hear it for myself. Most read in Fabulous 'Everything I knew and trusted felt like it had exploded. 'I was in disbelief. It felt like I was in a reality TV show, but it was my own life, and I had zero control over it. I hadn't asked for this.' The physiotherapist-turned-influencer watched the episode 10 times that day, trying to process the shocking news. Two weeks later, after widespread speculation about her relationship, Lilly released a statement confirming the rumours were true - Sophia and Cinzia had indeed been discussing her fiancé. She wrote on Instagram: 'On Thursday 9th November, I woke up to messages about a podcast episode discussing a relationship involving a newly engaged man, meeting a woman on his stag do, and subsequent encounters. 'It's heartbreaking to confirm this is true, and discovering it in this way has been devastating.' Four red flags your partner is cheating Private Investigator Aaron Bond from BondRees revealed four warning signs your partner might be cheating. They start to take their phone everywhere with them In close relationships, it's normal to know each other's passwords and use each other's phones, if their phone habits change then they may be hiding something. "You should also look at how they place their phone down when not in use. If they face the phone with the screen facing down, then they could be hiding something." They start telling you less about their day When partners cheat they can start to avoid you, this could be down to them feeling guilty or because it makes it easier for them to lie to you. "If you feel like your partner has suddenly begun to avoid you and they don't want to do things with you any more or they stop telling you about their day then this is another red flag." "Partners often avoid their spouses or tell them less about their day because cheating can be tough, remembering all of your lies is impossible and it's an easy way to get caught out," says Aaron. Their libido changes Your partner's libido can change for a range of reasons so it may not be a sure sign of cheating but it can be a red flag according to Aaron. Aaron says: "Cheaters often have less sex at home because they are cheating, but on occasions, they may also have more sex at home, this is because they feel guilty and use this increase in sex to hide their cheating. You may also find that your partner will start to introduce new things into your sex life that weren't there before." They become negative towards you Cheaters know that cheating is wrong and to them, it will feel good, this can cause tension and anxiety within themselves which they will need to justify. "To get rid of the tension they feel inside they will try to convince themselves that you are the problem and they will become critical of you out of nowhere. Maybe you haven't walked the dog that day, put the dishes away or read a book to your children before bedtime. A small problem like this can now feel like a big deal and if you experience this your partner could be cheating," warns Aaron. In the aftermath, Lilly took a hiatus from social media, despite building her entire career online and posting multiple times a day. 'I just wanted to disappear. I couldn't get away from it,' she recalled. 'I literally couldn't look in the mirror for about nine months afterwards because I was picking myself apart. 'What happened affected my family too. I literally couldn't look in the mirror for about nine months afterwards because I was picking myself apart Lilly Sabri 'Millions of people found out about my personal life before I did. 'It's humiliating. It was so humiliating for me.' After posting the statement, Lilly checked her social media to see if the podcast hosts had reached out to apologise, but they never did. A year and a half later, she still hasn't 'heard anything' from them. The emotional toll of the experience meant Lilly's physical and mental health took a significant hit, and she's had to pull herself out of some 'dark places' over the last 18 months. I was in disbelief. It felt like I was in a reality TV show, but it was my own life, and I had zero control over it. I hadn't asked for this Lilly Sabri 'It's obviously been a long time, a difficult time, but through that period, I've learned a lot, and I feel like I'm in a good place now,' she said. 'Mentally, I wasn't in a place to show up on social media, and that eventually affected my physical health as well. I needed to prioritise my mental health. 'If you'd asked me a year ago, I wouldn't have said I'd be able to do this right now. 'But finally, I feel ready.' Mentally, I wasn't in a place to show up on social media, and that eventually affected my physical health as well. I needed to prioritise my mental health Lilly Sabri Lilly, a qualified physiotherapist and Pilates instructor, has an impressive CV that includes the NHS and Watford Football Club, before she fully transitioned to social media. In 2021, she brought her 'Lean' method to the forefront with the launch of a fitness app and a range of nutritional products under the same name. Today, Lilly is the sole shareholder of her health brand, Lean, and she plans to integrate the mental health strategies she's learned into the business going forward. 'Without everything that happened, I wouldn't be here right now,' she said. 'I wouldn't have gotten through it. I can't tell you how much it saved me. 'This is a huge part of my new purpose. It's wellness, it's mental health, it's helping people. 'Whether it's a mental health crisis, anxiety, depression, or simply feeling overwhelmed, I want to help people with the skills I've learned, all while doing it with kindness.'
