Category Archives: Lean Tools

Posts related to different lean tools, often also known as the lean toolbox. Different methods that can be used to improve the shop floor, although it is risky to use methods on their own without a whole lean system.

Organize Your Production Sequence – 2: Job Shop

Job ShopJob shops are a manufacturing system where the machines are not arranged in the sequence of the work steps (as in a flow line). Rather, the flow of the part conforms to the arrangement of the machines.

This post looks in more detail at the job shop, its advantages and disadvantages, and where it may be useful. Continue reading Organize Your Production Sequence – 2: Job Shop

Organize Your Production Sequence – 1: Project Shop

There are different ways to organize your shop floor. You surely know the flow shop and the job shop. There is also a project shop (with many variants of names). While the flow shop is in many cases the ultimate goal, each shop has advantages and disadvantages. Let’s look at them in more detail, starting with the project shop. Continue reading Organize Your Production Sequence – 1: Project Shop

How to Determine Your Lot Size – Part 3

This is the third and final post on lot sizes (Part 1 and Part 2). After considering all the factors of the processes and inventories (changeover time, batch size, customer order size, and container and shipment size), we now look at how to set up the information flow. This is especially important if we want to have different lot sizes in different sections of our value stream. Continue reading How to Determine Your Lot Size – Part 3

How to Determine Your Lot Size – Part 2

A good lot size has a significant impact on the performance of the system. In this second post, I look at the influence of the machine batch size on the lot size. I also briefly go into the lot sizes for the processing industry, and also  administrative processes. In my next and last post I will look at how to manage different lot sizes in different parts of the value stream. Continue reading How to Determine Your Lot Size – Part 2

How to Determine Your Lot Size – Part 1

There are a few factors that can influence lot size: machine batch size, changeover time, size of the container, shipment sizes, and the size of your customers’ orders, which then are combined in the set up of the information flow. All of these factors can be influenced to move toward the true north of lot size one! Also, do not confuse the lot size with the number of parts per kanban. They are related but can be different. In this series of three posts, let me explain in more detail how the factors come together for you to determine the lot size of your processes. Continue reading How to Determine Your Lot Size – Part 1

The Lean Bucket Brigade – Part 2: Details and Caveats

In my last post I explained the basics of the bucket brigade as a self-organizing manufacturing line. The key to making this system work is the process for handing over the part to the next worker. An unsuitable hand-over could mean lots of waiting time for the workers. Hence, I would like to go into more detail on how to do the hand-over of the part. Continue reading The Lean Bucket Brigade – Part 2: Details and Caveats