All Posts and Pages

Archive of All Posts:

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

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