Tag Archives: Training

Taiichi Ohno’s Chalk Circle

Chalk CircleOne of the famous teaching methods by Taiichi Ohno is the chalk circle. The method itself is simple. A circle is drawn on the shop floor near a point of interest. A disciple is put in the circle and told not to leave it until he is picked up again by the teacher.

In this post I will explain a bit about the chalk circle, how to use it for teaching, and how to use it for yourself. Continue reading Taiichi Ohno’s Chalk Circle

Pay Attention to Details – Operator Training at Toyota and Scania

Watchmaker
It’s all in the details…

Often, implementing “lean” means management is picking the latest lean-related buzzword and telling their people to implement it. This is wrong on so many levels. For one, a lean project should always start with a problem, not a solution. On another level, good manufacturing is all about the nitty-gritty details. Both normal operations and improvement projects need a lot of attention to details. Unfortunately, this is frequently lacking in many companies. In this post I would like to show you the level of detail for operator training in some excellent companies. Continue reading Pay Attention to Details – Operator Training at Toyota and Scania

SMED – Creative Quick Changeover Exercises and Training

Fish Course
Set up exercises

One popular approach to battle waste is to streamline changeovers. Changing machines from one setup to another is often a time-consuming exercise. Hence, in lean manufacturing, reducing changeover times is a well-known method for improving efficiency. This post will show a number of examples where these quick changeovers (also known as SMED) can be practiced in an unusual environment. Continue reading SMED – Creative Quick Changeover Exercises and Training

Poka Yoke Training – Simple Mistake Proofing Game

Assembled Blue Dragon
Poka yoke anyone?

Mistake proofing (or Poka Yoke in Japanese) is one important way to avoid waste in lean manufacturing. In this post, I will present a small game that can be used to teach the basics of poka yoke easily and quickly. The game is based on Kinder Surprise eggs made by Ferrero, also known as a Kinder Egg. These eggs are available almost anywhere – except in the US, in which case there are some alternatives. Continue reading Poka Yoke Training – Simple Mistake Proofing Game