All Posts and Pages

Archive of All Posts:

  1. Just in Sequence Part 1 – What Is It?
  2. Different Ways to Establish a Pull System – Part 2
  3. Different Ways to Establish a Pull System – Part 1
  4. Visual Management
  5. Employee Motivation and Lean Implementation – Part 4: Respect for People
  6. Employee Motivation and Lean Implementation – Part 3: Lack of Respect
  7. Employee Motivation and Lean Implementation – Part 2: Money
  8. Employee Motivation and Lean Implementation – Part 1: Carrot and Stick
  9. Changeover Sequencing – Part 2
  10. Changeover Sequencing – Part 1
  11. On Running Changeovers
  12. The Phases of a Changeover
  13. What to Do with SMED: Reduce Lot Size or Increase Work Time?
  14. Where Lean Went Wrong – A Historical Perspective
  15. Strategies for Mass Customization
  16. Material Flow in the Arsenal of Venice 1797
  17. The Arsenal of Venice
  18. Pacing of Flow Lines 2 – Continuously Moving Line
  19. Pacing of Flow Lines 1 – Unstructured and Pulse Line
  20. Lean Is Tough – The Phases of a Lean Transformation
  21. Organize Your Production Sequence – 3: Flow Shop
  22. Organize Your Production Sequence – 2: Job Shop
  23. Organize Your Production Sequence – 1: Project Shop
  24. The Lean Mindset – Te & Kaffi in Iceland
  25. Lean Tales in Japan: The Japanese Supermarket Checkout
  26. The Lean Rabbit Chase in a U-Line
  27. 150th Anniversary of the Birth of Sakichi Toyoda
  28. The Chaku Chaku Line
  29. How to Determine Your Lot Size – Part 3
  30. How to Determine Your Lot Size – Part 2
  31. How to Determine Your Lot Size – Part 1
  32. The Lean Bucket Brigade – Part 2: Details and Caveats
  33. The Lean Bucket Brigade – Part 1: Overview
  34. Dealing with Uncertainty
  35. How to Ramp Up a Kanban System – Part 2: The Switch
  36. How to Ramp Up a Kanban System – Part 1: Preparation
  37. Kanban Card Design
  38. Interview on the David Pakman Show on the Future of Manufacturing
  39. Line Layout Strategies – Part 3: Merging
  40. Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines
  41. Line Layout Strategies – Part 1: The Big Picture
  42. Loss of Material: Theft!
  43. Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!
  44. Toyota’s and Denso’s Relentless Quest for Lot Size One
  45. “Lean Standard” ISO 18404 – A Questionable Idea …
  46. Volkswagen Supplier Relations Failure
  47. Can you tell your Bottleneck from your Inventory?
  48. The Many Different Flavors of the OEE
  49. AllAboutLean.com Is Now 3 Years Old!
  50. The History of Manufacturing – Part 4: Toyota and Lean
  51. The History of Manufacturing – Part 3: Luddism to Henry Ford
  52. The History of Manufacturing – Part 2: Middle Ages to Industrial Revolution
  53. The History of Manufacturing – Part 1: Prehistory to Antiquity
  54. Good and Bad Ways to Calculate the OEE
  55. How to Prioritize Your Work Orders – Prioritization of Made to Order
  56. How to Prioritize Your Work Orders – Prioritization of Made to Stock
  57. How to Prioritize Your Work Orders – The VIP Lane
  58. How to Prioritize Your Work Orders – Basics
  59. How to Make “Just in Time” Work – Part 2
  60. How to Make “Just in Time” Work – Part 1
  61. What Is “Just in Time”?
  62. Tales from Japan – Lean in the Japanese Public Toilet
  63. How Product Variants Influence Your Inventory
  64. The Relation between Inventory, Customer Takt, and Replenishment Time
  65. Using Lots of Effort and Money to Demotivate Your People
  66. The Curious Case of 100% Work Performance
  67. How Operators Hide the True Workload
  68. The Many Flavors of the PDCA
  69. Common Mistakes with the PDCA (and Some History)
  70. The Key to Lean – Plan, Do, Check, Act!
  71. Supermarket vs. FiFo – What Requires Less Inventory?
  72. The A3 Report – Part 3: Limitations and Common Mistakes
  73. The A3 Report – Part 2: Content
  74. The A3 Report – Part 1: Basics
  75. On the Benefits of a Pencil in Lean
  76. Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu
  77. Line Balancing Part 6 – Tips and Tricks for Balancing
  78. Line Balancing Part 5 – Balancing Using Paper
  79. Line Balancing Part 4 – OEE Usage and Flexibility
  80. Line Balancing Part 3 – OEE Caveats
  81. Line Balancing Part 2 – Duration of Tasks
  82. Line Balancing Part 1 – Data Overview
  83. The Challenges of Lean Administration
  84. The Problems of Cost Accounting with Lean
  85. Taiichi Ohno’s Chalk Circle
  86. A Critical Look at Industry 4.0
  87. Lean for Refugees
  88. How to Reduce Your Inventory
  89. Why Do We Have Inventory?
  90. American Automotive Market Strategy of Toyota and Others
  91. What Is Your Production Capacity?
  92. How to Use an Andon – and How Not To
  93. All About Andon
  94. The Three Fundamental Ways to Decouple Fluctuations
  95. Pay Attention to Details – Operator Training at Toyota and Scania
  96. Cycle Times for Manual Processes
  97. How to Measure Cycle Times – Part 2
  98. How to Measure Cycle Times – Part 1
  99. Pitfalls of Takt Times
  100. How to determine Takt Times
  101. On the Different Ways to Measure Production Speed
  102. All About Swim Lane Diagrams
  103. 2nd Birthday of AllAboutLean.com
  104. All About Spaghetti Diagrams
  105. Practical Tips for Value Stream Mapping
  106. Basics of Value Stream Maps
  107. Overview of Value Stream Mapping Symbols
  108. When to Do Value Stream Maps (and When Not!)
  109. Bubble Diagrams to Visualize Material Flow
  110. Visualize Your System – Overview of Diagrams in Manufacturing
  111. 230 Years of Interchangeable Parts – A Brief History
  112. A Eulogy for Little’s Law
  113. Theory and Practice of Supermarkets – Part 2
  114. Theory and Practice of Supermarkets – Part 1
  115. Why Pull Is So Great!
  116. The (True) Difference Between Push and Pull
  117. Twenty-five Years after Ohno – A Look Back
  118. How to Find a Good Lean Consultant
  119. Definition of Lean Production
  120. How to Make 5S Stick
  121. How 5S Works
  122. Muda, Mura, Muri: The Three Evils of Manufacturing
  123. More On Cuba’s Planned Economy: Cuban Industry
  124. Lies, Damned Lies, and KPI – Part 3 Countermeasures
  125. Lies, Damned Lies, and KPI – Part 2: Effects of Fudging
  126. 100th Anniversary of the Death of Frederick Winslow Taylor, the Father of Modern Scientific Management
  127. Lies, Damned Lies, and KPI – Part 1: Examples of Fudging
  128. The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
  129. How a Planned Economy Can Screw Up an Entire Country – Analogy between Cuba’s Communist Economy and Push Systems
  130. Benefits and Flaws of CONWIP in Comparison to Kanban
  131. Frequently Asked Questions on CONWIP Systems – Part 2
  132. Frequently Asked Questions on CONWIP Systems – Part 1
  133. Basics of CONWIP Systems (Constant Work in Progress)
  134. Shop Floor Etiquette – Part 2
  135. Shop Floor Etiquette – Part 1
  136. Introduction to One-Piece Flow Leveling – Part 2 Implementation
  137. Introduction to One-Piece Flow Leveling – Part 1 Theory
  138. The Folly of EPEI Leveling in Practice – Part 2
  139. The Folly of EPEI Leveling in Practice – Part 1
  140. Theory of Every Part Every Interval (EPEI) Leveling & Heijunka
  141. An Introduction to Capacity Leveling
  142. Why Leveling (Heijunka) is important
  143. A Critical Look at Goldrath’s Drum-Buffer-Rope Method
  144. Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
  145. Bottleneck Management Part 2 – Improve Bottleneck Planning
  146. Bottleneck Management Part 1 – Introduction and Utilization
  147. Common Mistakes of Top Executives – A look at “Undercover Boss”
  148. Top Five Cases When NOT to Use a FiFo
  149. Eight Rules for Total Gridlock in the Organization (Video)
  150. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)
  151. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)
  152. The Advantage of Handwritten Data on the Shop Floor
  153. The FiFo Calculator – Determining the Size of your Buffers
  154. Visual Management during World War II – A Visit to the Lascaris War Rooms in Malta
  155. Happy 1st Birthday AllAboutLean.com
  156. Determining the Size of Your FiFo Lane – The FiFo Formula
  157. Theory and Practice on FiFo Lanes – How Does FiFo Work in Lean Manufacturing?
  158. Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness
  159. Facing Change in Modern Manufacturing Systems – The Difference between Flexible, Agile, Reconfigurable, Robust, and Adaptable Manufacturing Systems
  160. The Hidden and not-so-hidden costs of Inventory
  161. Manufacturing – A key stepping stone on the Road to Prosperity
  162. The Bottleneck Walk – Practical Bottleneck Detection Part 2
  163. The Bottleneck Walk – Practical Bottleneck Detection Part 1
  164. Mathematically Accurate Bottleneck Detection 2 – The Active Period Method
  165. Mathematically Accurate Bottleneck Detection 1 – The Average Active Period Method
  166. Common Bottleneck Detection Methods that do NOT work!
  167. About Shifting Bottlenecks
  168. Culture of Quality – A Comparison of Toyota and GM Recalls
  169. Toyota Employee Relationship Crisis and Countermeasures 1990’s
  170. How Many Kanbans? – Estimation Approach and Maintenance
  171. How Many Kanbans? – The Kanban Formula, Part 2
  172. How Many Kanbans? – The Kanban Formula, Part 1
  173. Cost of Complexity
  174. The Problem of Losing Kanban – Different Kanban Types
  175. The Difference Between Lean and Six Sigma
  176. A Lean Obituary for Maybach – A Cautionary Tale About Cost of Complexity
  177. How to Manage Your Lean Projects – Prioritize
  178. How to Manage Your Lean Projects – Number of Active Projects
  179. How a Little Bit of Industrial Espionage Started the Industrial Revolution
  180. SMED – Creative Quick Changeover Exercises and Training
  181. The History of Quick Changeover (SMED)
  182. Quick Changeover Basics – SMED
  183. Poka Yoke Training – Simple Mistake Proofing Game
  184. Dress for Success in Lean Manufacturing
  185. Shigeo Shingo and the Art of Self Promotion
  186. Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant
  187. Lean is Zero Defects? – I don’t think so!
  188. Consistency at Toyota – The Board of Directors of the Toyota Motor Company
  189. Japanese Standard Pointing and Calling (Video)
  190. Value Stream Mapping – Why to Start at the Customer Side
  191. Simple Triangle Kanban System for Office Supplies
  192. Ten Rules When to Use a FIFO, When a Supermarket – The Rules
  193. Ten Rules When to Use a FIFO, When a Supermarket – Introduction
  194. Hell is Other People – Workplace Conflict between Managers and the Managed
  195. Internal Threat to the Toyota Production System Due to New Hiring Practices
  196. Extended Lean Tool Kit for Shop Floor Improvement Projects
  197. The Tale of Taylor and Gilbreth
  198. Know Your Priorities!
  199. Seven Gadgets for the Basic Lean Toolkit
  200. Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory
  201. Japanese Multidimensional Problem Solving
  202. Lean Where You Least Expect It – Toilet Paper Origami
  203. How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!
  204. Make Your Plant Tour a Success!
  205. Visit to Euromold for the Latest in 3D Printing
  206. Ancient Roman Management Techniques
  207. What the OEE is Good for … and What it’s Not
  208. Top Three Methods on how to Fudge Your OEE
  209. How to Measure OEE
  210. What is OEE? – Definition of OEE
  211. New Professor, New Blog

Archive of All Pages:

  1. “Faster, Better, Cheaper” in the History of Manufacturing
  2. About
  3. All Posts and Pages
  4. Ask me a Question!
  5. Awards
  6. Contact
  7. Credits
  8. Glossary of Lean Production Related Terms
  9. Professor Dr. Christoph Roser
  10. Publications and Presentations
  11. Services
  12. Some Legalese (Impressum)

Add a Comment