All Posts and Pages

Archive of All Posts:

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

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