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Archive of All Posts:

  1. Happy 11th Birthday, AllAboutLean.com!
  2. The Grand Tour of German Automotive—Volkswagen Emden
  3. The Grand Tour of German Automotive—Volkswagen Wolfsburg
  4. The Grand Tour of German Automotive—Audi Neckarsulm
  5. The Grand Tour of German Automotive—Audi Ingolstadt
  6. The Grand Tour of German Automotive—Porsche Assembly Lines
  7. The Grand Tour of German Automotive—Porsche Overview
  8. The Grand Tour of German Automotive—Daimler Truck Wörth
  9. The Grand Tour of German Automotive—Mercedes-Benz Rastatt
  10. The Grand Tour of German Automotive—Mercedes-Benz Bremen
  11. The Grand Tour of German Automotive—Mercedes-Benz Sindelfingen
  12. The Grand Tour of German Automotive—BMW Berlin Motorbikes
  13. The Grand Tour of German Automotive—BMW Leipzig
  14. The Grand Tour of German Automotive—BMW Munich
  15. The Grand Tour of German Automotive—Overview
  16. 3D Printing at Stratasys—3D Printing Markets
  17. 3D Printing at Stratasys—Printing Technologies
  18. A Frequent Mistake—Undoing an Assembly Line—Part 2
  19. A Frequent Mistake—Undoing an Assembly Line—Part 1
  20. The Evolution of Automotive Assembly Line—Part 2
  21. The Evolution of Automotive Assembly Line—Part 1
  22. The BMW Finger Line Layout
  23. Variable Takt at Fendt in Marktoberdorf—Part 3
  24. Variable Takt at Fendt in Marktoberdorf—Part 2
  25. Variable Takt at Fendt in Marktoberdorf—Part 1
  26. Using Empty Slots on the Assembly Line
  27. The Two Directions of Poka Yoke
  28. Different Aspects of Seeing a Shop Floor—Data
  29. Different Aspects of Seeing a Shop Floor—Gemba vs. Data
  30. Different Aspects of Seeing a Shop Floor—Unevenness, Overburden, and Safety
  31. Different Aspects of Seeing a Shop Floor—Visual Management, 5S, and Waste
  32. Different Aspects of Seeing a Shop Floor—Introduction
  33. Luxury Car Assembly at Audi and Daimler
  34. How to Pace Your Assembly Line
  35. Keep Calm and Stop the Line—Part 2
  36. Keep Calm and Stop the Line—Part 1
  37. Toyota Practical Problem Solving (PPS)—Monitor and Share
  38. Toyota Practical Problem Solving (PPS)—Countermeasures and Implement
  39. Toyota Practical Problem Solving (PPS)—Targets and Root Causes
  40. Toyota Practical Problem Solving (PPS)—Clarify
  41. Toyota Practical Problem Solving (PPS)—Introduction
  42. What Exactly Is Overburden (Muri)?
  43. Lessons Learned from the Toyota KPI Dashboard for Your Own Dashboard
  44. The Toyota KPI Dashboard—Production Plan
  45. The Toyota KPI Dashboard—Human Resources
  46. The Toyota KPI Dashboard—Cost
  47. The Toyota KPI Dashboard—Productivity
  48. The Toyota KPI Dashboard—Quality
  49. The Toyota KPI Dashboard—Safety
  50. The Toyota KPI Dashboard—Overview
  51. Dos and Do Nots for KPIs
  52. Ramp-Up and Ramp-Down of Production
  53. Preparation for Ramp Up and Down of Production
  54. Happy 10th Birthday, AllAboutLean.com
  55. When to Use Standards…and When Not
  56. Different Ways to Do Kaizen
  57. The Soft Power of the Toyota Production System—Yokoten, Nemawashi, and More
  58. Continuously Moving Assembly Line—Speed Limitations
  59. Continuously Moving Assembly Line—Special Situations
  60. Continuously Moving Assembly Line—How to Do Line Balancing
  61. Continuously Moving Assembly Line—Speed, Work Content, and Length
  62. The Particularities of Continuously Moving Assembly Lines
  63. How to Do Make-or-Buy
  64. Make or Buy: How Not to Do It
  65. Flexible Multi-Model Assembly Line at Toyota
  66. Training Within Industry—Second-Line Supervisor Job Instructions
  67. Real vs. Planned Data in Pull Systems
  68. The Difference between the Toyota Production System and Lean Manufacturing
  69. KUKA FAMULUS Turns 50—The First Modern Industrial Robot
  70. When to Use a Milk Run
  71. Stack Lights—Visual Management Done Easy
  72. SMED 2.0—A Changeover for the Changeover
  73. The Danger of Management by Numbers
  74. Making the Problem go Away Is NOT Improvement
  75. On the Team Structure at Toyota
  76. Adding Another Axis to the Qualification Matrix—Products
  77. How to Use a Qualification Matrix
  78. How to Establish a Qualification Matrix
  79. On the Benefits of Putting Your Processes Close Together
  80. Steps Toward One-Piece Flow
  81. Akio Toyoda Steps Down as Toyota CEO
  82. What Are the Advantages of One-Piece Flow?
  83. The Impact of ChatGPT on the Future of Work
  84. The Limits of Work Standards
  85. What’s Buzzing?—Vibration Sensors in Industry
  86. The Difficulties of Dazzling Digital Shop Floor Dashboards
  87. Toyota’s New Type of Flexible Assembly Lines—Takaoka Line #2
  88. Omotenashi in Product Design
  89. The Van of Nerds in France—Trains and Cars
  90. The Van of Nerds in France—Internal Logistics in Well Exploration and Military Products
  91. The Van of Nerds in France—Aircraft Engines and Parts
  92. The Van of Nerds in France—Research Laboratories
  93. The Van of Nerds in France—Overview and Aircrafts
  94. Toyota’s Master Craftsmen: Takumi
  95. What Is Ikigai?
  96. How to Reduce Part Variants
  97. How to Reduce Product Variants
  98. How to Reduce Your Lot Size Part 3—Customer, Machine, Leveling, and Tradition
  99. How to Reduce Your Lot Size Part 2—Changeover, Container, and Shipments
  100. How to Reduce Your Lot Size Part 1—Introduction
  101. Why FIFO: The Benefits of First In, First Out
  102. What Should Be Your Target OEE?
  103. Should You Split Your Production System into Two?
  104. This is NOT Lean: Lean Staffing
  105. 250 Years of the Cromford Cotton Mill – Start of the Industrial Revolution
  106. Happy 9th Birthday, AllAboutLean.com
  107. Examples of Job Shop to Flow Shop Conversions
  108. Manufacturing in a War Zone – Part 2
  109. Manufacturing in a War Zone – Part 1
  110. What is One-Piece Flow?
  111. What Is Flow?
  112. How IKEA Uses Drones for Inventory Management
  113. Drones in Manufacturing
  114. The 6R Goals of Lean Manufacturing
  115. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 3
  116. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 2
  117. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 1
  118. Virtual Reality Factory for Training and Teaching
  119. Where to Start Your Kaizen?
  120. The Modern Way to Buy Screws
  121. The Problem of Industry 4.0: Data! – Part 2
  122. The Problem of Industry 4.0: Data! – Part 1
  123. Evolution of Process Placement at Toyota – Part 2
  124. Evolution of Process Placement at Toyota – Part 1
  125. Material Flow and Traffic Flow – An Analogy
  126. 250 Years after the Birth of Eli Terry
  127. On Standard Tools and Standard Solutions…
  128. 50 Years of SAP–Blessing or a Curse?
  129. How Managers Drove Boeing into the Ground…
  130. A Few More Turns on the Changeover Wheel – Part 5: Frequently Asked Questions
  131. A Few More Turns on the Changeover Wheel – Part 4: Options for Prioritizing
  132. A Few More Turns on the Changeover Wheel – Part 3: Prioritizing Jobs
  133. A Few More Turns on the Changeover Wheel – Part 2: Improving the Sequence
  134. A Few More Turns on the Changeover Wheel – Part 1: Creating a Sequence
  135. AI in Manufacturing: Hype or Helpful?
  136. What Percentage Value Add to Expect for Manual Work?
  137. How to Estimate Value Add for Manual Work – How to See Waste!
  138. On Workplace Safety
  139. Alec Baldwin and Workplace Safety
  140. 50 Years after the Death of Lillian Evelyn Gilbreth
  141. Changeover Sequencing under Duress: Problems with Make and Deliver
  142. Changeover Sequencing under Duress: Problems with Source
  143. The Benefits of Mass Production
  144. Make-to-Order vs Make-to-Stock: Additional Decision Factors
  145. Make-to-Order vs Make-to-Stock: The ABC XYZ Analysis
  146. When to Produce Make-to-Order, When Make-to-Stock?
  147. Replenishment Time Stability for Changeover Sequencing
  148. How to Prioritize in Changeover Sequencing
  149. Can You Plan Around Your Fluctuations?
  150. The Boss Knows Best … or Does He?
  151. Military Leadership and Disobedience
  152. Ten Years of Industry 4.0-Quo Vadis?
  153. Work Improvement before Equipment Improvement
  154. How to Convince Your People to Do a Lean Transformation
  155. About the Value of Disagreement for Leadership
  156. About Just in Time and Fluctuations (Like… a Pandemic…)
  157. Standards Part 9: Leader Standard Work
  158. Happy 8th Birthday AllAboutLean.com
  159. Standards Part 8: Example for a Work Standard
  160. Standards Part 7: How to Write a Work Standard
  161. Standards Part 6: Standardized Work
  162. Standards Part 5: How to Use and Improve a Standard
  163. Standards Part 4: How to Write a Standard (Continued)
  164. Standards Part 3: How to Write a Standard
  165. Standards Part 2: Why and Where to Do Standards
  166. Standards Part 1: What Are Standards?
  167. How Much to Adjust the Pull Inventory Limit
  168. Behavior of a Kanban Supermarket
  169. Performance Comparison of Job Shop and Flow Shop
  170. What Different Pull Systems Can Be Combined?
  171. Which Pull System Is Right for You?
  172. What Are the Criteria to Decide on a Pull System?
  173. The Different Ways to Establish Pull Production
  174. Pull: A Way Forward for Supply Chains – Guest Post by John Shook
  175. An Alternative Structure for Total Productive Maintenance
  176. How to Do Reactive Maintenance
  177. The Pillars of TPM – The Missing Pillar Reactive Maintenance?
  178. The Pillars of TPM – Quality, Training, Administration, and Safety
  179. The Pillars of TPM – Early Equipment Management
  180. The Pillars of TPM – Planned Maintenance
  181. The Pillars of TPM – Autonomous Maintenance
  182. The Pillars of TPM – Focused Improvement
  183. An Overview of the Eight Pillars of Total Productive Maintenance
  184. What Are the Goals of Maintenance?
  185. A Brief History of Maintenance
  186. What Is a Good Minimum for the Supermarket?
  187. How to Use a Minimum in a Supermarket
  188. Manufacturing Drives Prosperity
  189. Respect for People – It’s Difficult…
  190. Respect for People – Why and How
  191. Respect for People – Introduction
  192. Reducing Lead Time 4 – Development
  193. Reducing Lead Time 3 – Throughput and Lot Size
  194. Reducing Lead Time 2 – Fluctuations and Utilization
  195. Reducing Lead Time 1 – Inventory
  196. What Is True North in Lean?
  197. The Baton Touch Flow Line
  198. How to Learn Lean
  199. The Impact of Brexit on Supply Chains
  200. Reducing Fluctuations Downstream
  201. Reducing Fluctuations on Your Shop Floor
  202. Reducing Fluctuations Upstream
  203. Structure for Reducing Fluctuations
  204. Why Are Fluctuations So Bad?
  205. How to Roll Out a Lean Transformation
  206. Key Points for a Lean Transformation
  207. How NOT to Do a Lean Transformation – A Case Study of GM
  208. How to Do a Lean Transformation – The Toyota Approach
  209. When NOT to Balance a Line
  210. Happy 7th Birthday AllAboutLean.com
  211. Toyota’s Six Rules for Kanban
  212. How the Corona Virus affects Logistics
  213. On the Safety of Workers During Corona – Part 2
  214. On the Safety of Workers During Corona – Part 1
  215. Design for X
  216. Design for Assembly Questions – Part 3
  217. Design for Assembly Questions – Part 2
  218. Design for Assembly Questions – Part 1
  219. Design for Manufacturing Questions
  220. Design for Manufacturing and Assembly Workshop Preparation
  221. Design for Manufacturing and Assembly Basics
  222. How to Convert a Job Shop into a Flow Shop – Part 2
  223. How to Convert a Job Shop into a Flow Shop – Part 1
  224. Why Are Job Shops Always Such a Chaotic Mess? Part 2
  225. Why Are Job Shops Always Such a Chaotic Mess? Part 1
  226. How to Conduct a Shop Floor Meeting
  227. How to Set Up a Shop Floor Meeting – Part 2
  228. How to Set Up a Shop Floor Meeting – Part 1
  229. When NOT to Pull!
  230. American Factory – Documentary of a Chinese Automotive Factory in the USA
  231. Fictional Movie on US-Japan Automotive Culture Clash – Gung Ho
  232. The Amazon Robotics Family: Kiva, Pegasus, Xanthus, and more…
  233. Amazon Kiva Storage Strategies
  234. Where Is All the Toilet Paper? Don’t Worry, It Is coming!
  235. Storage Strategies – Mixed Systems and Review
  236. Storage Strategies – Random Chaotic and ABC
  237. Storage Strategies – Fixed Location
  238. Storage Strategies – Even More Stacking Options
  239. Storage Strategies – Stacking Options
  240. Flexible Manpower Lines 4 – How-To do Flexible Manpower Lines
  241. Flexible Manpower Lines 3 – Example Line
  242. Flexible Manpower Lines 2 – Alternatives and Example
  243. Flexible Manpower Lines 1 – Introduction
  244. What Is Kaizen?
  245. 225th Anniversary of the Death of Josiah Wedgwood – Father of Science in Manufacturing
  246. 115 Years after the Birth of Joseph Juran
  247. When and How to Use Extra Kanban
  248. More Reasons for Working Less
  249. One Up One Down – Approach to Manage Manual Production Lines
  250. The Inner Workings of Amazon Fulfillment Centers – Part 6
  251. The Inner Workings of Amazon Fulfillment Centers – Part 5
  252. The Inner Workings of Amazon Fulfillment Centers – Part 4
  253. The Inner Workings of Amazon Fulfillment Centers – Part 3
  254. The Inner Workings of Amazon Fulfillment Centers – Part 2
  255. The Inner Workings of Amazon Fulfillment Centers – Part 1
  256. Industry 4.0 Tour in Germany – A Van Full of Nerds – Presentations and Tryouts
  257. Industry 4.0 Tour in Germany – A Van Full of Nerds – Kärcher and Siemens
  258. Industry 4.0 Tour in Germany – A Van Full of Nerds – Bosch Reutlingen Wafer Fab
  259. Industry 4.0 Tour in Germany – A Van Full of Nerds – Trumpf Gerlingen
  260. Industry 4.0 Tour in Germany – A Van Full of Nerds – ABB Stotz-Kontakt
  261. Industry 4.0 Tour in Germany – A Van Full of Nerds – Overview and Audi
  262. Happy 6th Birthday, AllAboutLean.com
  263. Cardboard Engineering – Alternatives
  264. Cardboard Engineering – Workshop
  265. Cardboard Engineering – Preparation
  266. Mixed Model Sequencing – Summary
  267. Mixed Model Sequencing – Complex Example Verification
  268. Mixed Model Sequencing – Complex Example Sequencing 2
  269. Mixed Model Sequencing – Complex Example Sequencing 1
  270. Mixed Model Sequencing – Complex Example Data Basis
  271. Mixed Model Sequencing – Complex Example Introduction
  272. Mixed Model Sequencing – Basic Example Sequencing
  273. Mixed Model Sequencing – Basic Example Workload and Buffering
  274. Mixed Model Sequencing – Basic Example Introduction
  275. Mixed Model Sequencing – Adjust Capacity
  276. Mixed Model Sequencing – Just Make the Problem Go Away
  277. Mixed Model Sequencing – Introduction
  278. On Adjusting Supervisor Workload
  279. On the Span of Control
  280. Diseconomies of Scale
  281. Relation between Quantity and Cost in Manufacturing
  282. Maintaining Weak FIFO in Parallel FIFO Lanes
  283. Maintaining Strong FIFO in Parallel FIFO Lanes
  284. The Power of Six: Time and Money for Parts of Your Value Stream
  285. The Power of Six: Relation between Time and Money in Manufacturing
  286. 150 Years after the Birth of Albert Kahn
  287. The Toyoda Model G Loom (with Videos)
  288. Production Control with COBACABANA
  289. Production Sequences: FCFS, EDD, and Others
  290. Delivery Sequences: FIFO, LIFO, and Others
  291. How to Make CONWIP Loops
  292. Should You Use Physical or Digital Kanban Cards?
  293. Hoshin Kanri and the Kanri Noryoku Program: Rejuvenating Toyota
  294. Hoshin Kanri – Part 4: The X-Matrix?
  295. Hoshin Kanri – Part 3: Hierarchical Hoshins
  296. Hoshin Kanri – Part 2: PDCA
  297. Hoshin Kanri – Part 1: The To-Do List
  298. How Cheap Can You Make it?
  299. 25 Years after W. Edwards Deming
  300. Point-of-Use Provider Routing
  301. Point-of-Use Provider Calculations
  302. Introduction to Point-of-Use Providers (or Mizusumashi)
  303. Lean Construction
  304. Example of Problem Solving – Japanese Men’s Relay Team Rio 2016
  305. A Good Standard Needs No Explanation
  306. External Milk Runs
  307. Frequently Asked Questions for Milk Runs
  308. Milk Run Layout
  309. Calculating the Material for Your Milk Run
  310. Milk Run Basics
  311. Introduction to Milk Runs
  312. Just in Time at Hyundai Mobis in Korea
  313. Toyota Kata
  314. Happy 5th Birthday AllAboutLean.com
  315. Calculating the Number of POLCA Cards
  316. Advantages and Disadvantages of POLCA
  317. What Is POLCA?
  318. Lean and Industry 4.0
  319. Examples of Jidoka
  320. The Philosophy and Practicality of Jidoka
  321. What Exactly Is Jidoka?
  322. All About 5 Why
  323. Toyota Standard Work – Part 3: Standard Work Layout
  324. Toyota Standard Work – Part 2: Standard Work Combination Table
  325. Toyota Standard Work – Part 1: Production Capacity
  326. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 2
  327. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 1
  328. My Workshop Structure for Creative Problem Solving
  329. Creative Provocation, Reverse Brainstorming, and Analogy
  330. Fishbone Diagrams and Mind Maps
  331. How to Do Brainstorming
  332. Leading with Confidence
  333. Effect of Prioritization on Waiting Times
  334. The Grand Tour of Japanese Automotive – Subaru
  335. The Grand Tour of Japanese Automotive – Suzuki
  336. The Grand Tour of Japanese Automotive – Mazda
  337. The Grand Tour of Japanese Automotive – Mitsubishi
  338. The Grand Tour of Japanese Automotive – Honda Kumamoto
  339. The Grand Tour of Japanese Automotive – Honda Sayama
  340. The Grand Tour of Japanese Automotive – Nissan
  341. The Grand Tour of Japanese Automotive – Overview and Toyota
  342. Continued Evolution of the Toyota Assembly Line
  343. More on TWI Programs
  344. JM: Training within Industry – Job Methods
  345. JR: Training within Industry – Job Relations
  346. JI: Training within Industry – Job Instructions
  347. Training within Industry – TWI – Oldies but Goldies
  348. Heroes, Firefighting, and Corporate Culture
  349. The Dark Side of Japanese Working Society
  350. The Toyota Employee Evaluation System
  351. Anatomy of the Toyota Kanban
  352. Monozukuri – Japanese Work Ethics
  353. A Small Dice Game for the Kingman Formula
  354. Twelve Ways to Create Space around Your Assembly – Part 2
  355. Twelve Ways to Create Space around Your Assembly – Part 1
  356. Structured Approach to Material Supply for Assembly – Part 2
  357. Structured Approach to Material Supply for Assembly – Part 1
  358. The Challenges of Material Supply for Assembly
  359. Karakuri Kaizen Examples
  360. Fundamentals of Karakuri Kaizen
  361. Introduction to Karakuri Kaizen
  362. Industry 4.0 – What Works, What Doesn’t
  363. How to Deal With Long Delivery Times
  364. The Kingman Formula – Variation, Utilization, and Lead Time
  365. Ship to Line
  366. Happy 4th Birthday AllAboutLean.com
  367. Just in Sequence Part 3 – What Can Go Wrong
  368. Just in Sequence Part 2 – How to Do It
  369. Just in Sequence Part 1 – What Is It?
  370. Different Ways to Establish a Pull System – Part 2
  371. Different Ways to Establish a Pull System – Part 1
  372. How to See Visual Management
  373. Employee Motivation and Lean Implementation – Part 4: Respect for People
  374. Employee Motivation and Lean Implementation – Part 3: Lack of Respect
  375. Employee Motivation and Lean Implementation – Part 2: Money
  376. Employee Motivation and Lean Implementation – Part 1: Carrot and Stick
  377. Changeover Sequencing – Part 2
  378. Changeover Sequencing – Part 1
  379. On Running Changeovers
  380. The Phases of a Changeover
  381. What to Do with SMED: Reduce Lot Size or Increase Work Time?
  382. Where Lean Went Wrong – A Historical Perspective
  383. Strategies for Mass Customization
  384. Material Flow in the Arsenal of Venice 1797
  385. The Arsenal of Venice
  386. Pacing of Flow Lines 2 – Continuously Moving Line
  387. Pacing of Flow Lines 1 – Unstructured and Pulse Line
  388. Lean Is Tough – The Phases of a Lean Transformation
  389. Organize Your Production Sequence – 3: Flow Shop
  390. Organize Your Production Sequence – 2: Job Shop
  391. Organize Your Production Sequence – 1: Project Shop
  392. The Lean Mindset – Te & Kaffi in Iceland
  393. Lean Tales in Japan: The Japanese Supermarket Checkout
  394. The Lean Rabbit Chase in a U-Line
  395. 150th Anniversary of the Birth of Sakichi Toyoda
  396. The Chaku Chaku Line
  397. How to Determine Your Lot Size – Part 3
  398. How to Determine Your Lot Size – Part 2
  399. How to Determine Your Lot Size – Part 1
  400. The Lean Bucket Brigade – Part 2: Details and Caveats
  401. The Lean Bucket Brigade – Part 1: Overview
  402. Dealing with Uncertainty
  403. How to Ramp Up a Kanban System – Part 2: The Switch
  404. How to Ramp Up a Kanban System – Part 1: Preparation
  405. Kanban Card Design
  406. Interview on the David Pakman Show on the Future of Manufacturing
  407. Line Layout Strategies – Part 3: Merging
  408. Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines
  409. Line Layout Strategies – Part 1: The Big Picture
  410. Loss of Material: Theft!
  411. Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!
  412. Toyota’s and Denso’s Relentless Quest for Lot Size One
  413. “Lean Standard” ISO 18404 – A Questionable Idea …
  414. Volkswagen Supplier Relations Failure
  415. Can you tell your Bottleneck from your Inventory?
  416. The Many Different Flavors of the OEE
  417. Happy 3rd Birthday AllAboutLean.com
  418. The History of Manufacturing – Part 4: Toyota and Lean
  419. The History of Manufacturing – Part 3: Luddism to Henry Ford
  420. The History of Manufacturing – Part 2: Middle Ages to Industrial Revolution
  421. The History of Manufacturing – Part 1: Prehistory to Antiquity
  422. Good and Bad Ways to Calculate the OEE
  423. How to Prioritize Your Work Orders – Prioritization of Made to Order
  424. How to Prioritize Your Work Orders – Prioritization of Made to Stock
  425. How to Prioritize Your Work Orders – The VIP Lane
  426. How to Prioritize Your Work Orders – Basics
  427. How to Make “Just in Time” Work – Part 2
  428. How to Make “Just in Time” Work – Part 1
  429. What Is “Just in Time”?
  430. Tales from Japan – Lean in the Japanese Public Toilet
  431. How Product Variants Influence Your Inventory
  432. The Relation between Inventory, Customer Takt, and Replenishment Time
  433. Using Lots of Effort and Money to Demotivate Your People
  434. The Curious Case of 100% Work Performance
  435. How Operators Hide the True Workload
  436. The Many Flavors of the PDCA
  437. Common Mistakes with the PDCA (and Some History)
  438. The Key to Lean – Plan, Do, Check, Act!
  439. Supermarket vs. FiFo – What Requires Less Inventory?
  440. The A3 Report – Part 3: Limitations and Common Mistakes
  441. The A3 Report – Part 2: Content
  442. The A3 Report – Part 1: Basics
  443. On the Benefits of a Pencil in Lean
  444. Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu
  445. Line Balancing Part 6 – Tips and Tricks for Balancing
  446. Line Balancing Part 5 – Balancing Using Paper
  447. Line Balancing Part 4 – OEE Usage and Flexibility
  448. Line Balancing Part 3 – OEE Caveats
  449. Line Balancing Part 2 – Duration of Tasks
  450. Line Balancing Part 1 – Data Overview
  451. The Challenges of Lean Administration
  452. The Problems of Cost Accounting with Lean
  453. Taiichi Ohno’s Chalk Circle
  454. A Critical Look at Industry 4.0
  455. Lean for Refugees
  456. How to Reduce Your Inventory
  457. Why Do We Have Inventory?
  458. American Automotive Market Strategy of Toyota and Others
  459. What Is Your Production Capacity?
  460. How to Use an Andon – and How Not To
  461. All About Andon
  462. The Three Fundamental Ways to Decouple Fluctuations
  463. Pay Attention to Details – Operator Training at Toyota and Scania
  464. Cycle Times for Manual Processes
  465. How to Measure Cycle Times – Part 2
  466. How to Measure Cycle Times – Part 1
  467. Pitfalls of Takt Times
  468. How to determine Takt Times
  469. On the Different Ways to Measure Production Speed
  470. All About Swim Lane Diagrams
  471. Happy 2nd Birthday AllAboutLean.com
  472. All About Spaghetti Diagrams
  473. Practical Tips for Value Stream Mapping
  474. Basics of Value Stream Maps
  475. Overview of Value Stream Mapping Symbols
  476. When to Do Value Stream Maps (and When Not!)
  477. Bubble Diagrams to Visualize Material Flow
  478. Visualize Your System – Overview of Diagrams in Manufacturing
  479. 230 Years of Interchangeable Parts – A Brief History
  480. A Eulogy for Little’s Law
  481. Theory and Practice of Supermarkets – Part 2
  482. Theory and Practice of Supermarkets – Part 1
  483. Why Pull Is So Great!
  484. The (True) Difference Between Push and Pull
  485. Twenty-five Years after Ohno – A Look Back
  486. How to Find a Good Lean Consultant
  487. Definition of Lean Production
  488. How to Make 5S Stick
  489. How 5S Works
  490. Muda, Mura, Muri: The Three Evils of Manufacturing
  491. More On Cuba’s Planned Economy: Cuban Industry
  492. Lies, Damned Lies, and KPI – Part 3: Countermeasures
  493. Lies, Damned Lies, and KPI – Part 2: Effects of Fudging
  494. 100th Anniversary of the Death of Frederick Winslow Taylor, the Father of Modern Scientific Management
  495. Lies, Damned Lies, and KPI – Part 1: Examples of Fudging
  496. The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
  497. How a Planned Economy Can Screw Up an Entire Country – Analogy between Cuba’s Communist Economy and Push Systems
  498. Benefits and Flaws of CONWIP in Comparison to Kanban
  499. Frequently Asked Questions on CONWIP Systems – Part 2
  500. Frequently Asked Questions on CONWIP Systems – Part 1
  501. Basics of CONWIP Systems (Constant Work in Progress)
  502. Shop Floor Etiquette – Part 2
  503. Shop Floor Etiquette – Part 1
  504. Introduction to One-Piece Flow Leveling – Part 2 Implementation
  505. Introduction to One-Piece Flow Leveling – Part 1 Theory
  506. The Folly of EPEI Leveling in Practice – Part 2
  507. The Folly of EPEI Leveling in Practice – Part 1
  508. Theory of Every Part Every Interval (EPEI) Leveling & Heijunka
  509. An Introduction to Capacity Leveling
  510. Why Leveling (Heijunka) is important
  511. A Critical Look at Goldratt’s Drum-Buffer-Rope Method
  512. Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
  513. Bottleneck Management Part 2 – Improve Bottleneck Planning
  514. Bottleneck Management Part 1 – Introduction and Utilization
  515. Common Mistakes of Top Executives – A look at “Undercover Boss”
  516. Top Five Cases When NOT to Use a FiFo
  517. Eight Rules for Total Gridlock in the Organization (Video)
  518. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)
  519. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)
  520. The Advantage of Handwritten Data on the Shop Floor
  521. The FiFo Calculator – Determining the Size of your Buffers
  522. Visual Management during World War II – A Visit to the Lascaris War Rooms in Malta
  523. Happy 1st Birthday AllAboutLean.com
  524. Determining the Size of Your FiFo Lane – The FiFo Formula
  525. Theory and Practice on FiFo Lanes – How Does FiFo Work in Lean Manufacturing?
  526. Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness
  527. Facing Change in Modern Manufacturing Systems – The Difference between Flexible, Agile, Reconfigurable, Robust, and Adaptable Manufacturing Systems
  528. The Hidden and not-so-hidden costs of Inventory
  529. Manufacturing – A key stepping stone on the Road to Prosperity
  530. The Bottleneck Walk – Practical Bottleneck Detection Part 2
  531. The Bottleneck Walk – Practical Bottleneck Detection Part 1
  532. Mathematically Accurate Bottleneck Detection 1 – The Average Active Period Method
  533. Mathematically Accurate Bottleneck Detection 2 – The Active Period Method
  534. Common Bottleneck Detection Methods that do NOT work!
  535. About Shifting Bottlenecks
  536. Culture of Quality – A Comparison of Toyota and GM Recalls
  537. Toyota Employee Relationship Crisis and Countermeasures 1990’s
  538. How Many Kanbans? – Estimation Approach and Maintenance
  539. How Many Kanbans? – The Kanban Formula, Part 2
  540. How Many Kanbans? – The Kanban Formula, Part 1
  541. Cost of Complexity
  542. The Problem of Losing Kanban – Different Kanban Types
  543. The Difference Between Lean and Six Sigma
  544. A Lean Obituary for Maybach – A Cautionary Tale About Cost of Complexity
  545. How to Manage Your Lean Projects – Prioritize
  546. How to Manage Your Lean Projects – Number of Active Projects
  547. How a Little Bit of Industrial Espionage Started the Industrial Revolution
  548. SMED – Creative Quick Changeover Exercises and Training
  549. The History of Quick Changeover (SMED)
  550. Quick Changeover Basics – SMED
  551. Poka Yoke Training – Simple Mistake Proofing Game
  552. Dress for Success in Lean Manufacturing
  553. On the Lean Guru Shigeo Shingo
  554. Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant
  555. Lean is Zero Defects? – I don’t think so!
  556. Consistency at Toyota – The Board of Directors of the Toyota Motor Company
  557. Japanese Standard Pointing and Calling (Video)
  558. Value Stream Mapping – Why to Start at the Customer Side
  559. Simple Triangle Kanban System for Office Supplies
  560. Ten Rules When to Use a FIFO, When a Supermarket – The Rules
  561. Ten Rules When to Use a FIFO, When a Supermarket – Introduction
  562. Hell is Other People – Workplace Conflict between Managers and the Managed
  563. Internal Threat to the Toyota Production System Due to New Hiring Practices
  564. Extended Lean Tool Kit for Shop Floor Improvement Projects
  565. The Tale of Taylor and Gilbreth
  566. Know Your Priorities!
  567. Seven Gadgets for the Basic Lean Toolkit
  568. Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory
  569. Japanese Multidimensional Problem Solving
  570. Lean Where You Least Expect It – Toilet Paper Origami
  571. How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!
  572. Make Your Plant Tour a Success!
  573. Visit to Euromold for the Latest in 3D Printing
  574. Ancient Roman Management Techniques
  575. What the OEE is Good for … and What it’s Not
  576. Top Three Methods on how to Fudge Your OEE
  577. How to Measure OEE
  578. What is OEE? – Definition of OEE
  579. New Professor, New Blog

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