Archive of All Posts:
- Milk Run Layout
- Calculating the Material for Your Milk Run
- Milk Run Basics
- Introduction to Milk Runs
- Just in Time at Hyundai Mobis in Korea
- Toyota Kata
- Happy 5th Birthday AllAboutLean.com
- Calculating the Number of POLCA Cards
- Advantages and Disadvantages of POLCA
- What Is POLCA?
- Lean and Industry 4.0
- Examples of Jidoka
- The Philosophy and Practicality of Jidoka
- What Exactly Is Jidoka?
- All About 5 Why
- Toyota Standard Work – Part 3: Standard Work Layout
- Toyota Standard Work – Part 2: Standard Work Combination Table
- Toyota Standard Work – Part 1: Production Capacity
- Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 2
- Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 1
- My Workshop Structure for Creative Problem Solving
- Creative Provocation, Reverse Brainstorming, and Analogy
- Fishbone Diagrams and Mind Maps
- How to Do Brainstorming
- Leading with Confidence
- Effect of Prioritization on Waiting Times
- The Grand Tour of Japanese Automotive – Subaru
- The Grand Tour of Japanese Automotive – Suzuki
- The Grand Tour of Japanese Automotive – Mazda
- The Grand Tour of Japanese Automotive – Mitsubishi
- The Grand Tour of Japanese Automotive – Honda Kumamoto
- The Grand Tour of Japanese Automotive – Honda Sayama
- The Grand Tour of Japanese Automotive – Nissan
- The Grand Tour of Japanese Automotive – Overview and Toyota
- Continued Evolution of the Toyota Assembly Line
- More on TWI Programs
- JM: Training within Industry – Job Methods
- JR: Training within Industry – Job Relations
- JI: Training within Industry – Job Instructions
- Training within Industry – TWI – Oldies but Goldies
- Heroes, Firefighting, and Corporate Culture
- The Dark Side of Japanese Working Society
- The Toyota Employee Evaluation System
- Anatomy of the Toyota Kanban
- Monozukuri – Japanese Work Ethics
- A Small Dice Game for the Kingman Formula
- Twelve Ways to Create Space around Your Assembly – Part 2
- Twelve Ways to Create Space around Your Assembly – Part 1
- Structured Approach to Material Supply for Assembly – Part 2
- Structured Approach to Material Supply for Assembly – Part 1
- The Challenges of Material Supply for Assembly
- Karakuri Kaizen Examples
- Fundamentals of Karakuri Kaizen
- Introduction to Karakuri Kaizen
- Industry 4.0 – What Works, What Doesn’t
- How to Deal With Long Delivery Times
- The Kingman Formula – Variation, Utilization, and Lead Time
- Ship to Line
- Happy 4th Birthday AllAboutLean.com
- Just in Sequence Part 3 – What Can Go Wrong
- Just in Sequence Part 2 – How to Do It
- Just in Sequence Part 1 – What Is It?
- Different Ways to Establish a Pull System – Part 2
- Different Ways to Establish a Pull System – Part 1
- Visual Management
- Employee Motivation and Lean Implementation – Part 4: Respect for People
- Employee Motivation and Lean Implementation – Part 3: Lack of Respect
- Employee Motivation and Lean Implementation – Part 2: Money
- Employee Motivation and Lean Implementation – Part 1: Carrot and Stick
- Changeover Sequencing – Part 2
- Changeover Sequencing – Part 1
- On Running Changeovers
- The Phases of a Changeover
- What to Do with SMED: Reduce Lot Size or Increase Work Time?
- Where Lean Went Wrong – A Historical Perspective
- Strategies for Mass Customization
- Material Flow in the Arsenal of Venice 1797
- The Arsenal of Venice
- Pacing of Flow Lines 2 – Continuously Moving Line
- Pacing of Flow Lines 1 – Unstructured and Pulse Line
- Lean Is Tough – The Phases of a Lean Transformation
- Organize Your Production Sequence – 3: Flow Shop
- Organize Your Production Sequence – 2: Job Shop
- Organize Your Production Sequence – 1: Project Shop
- The Lean Mindset – Te & Kaffi in Iceland
- Lean Tales in Japan: The Japanese Supermarket Checkout
- The Lean Rabbit Chase in a U-Line
- 150th Anniversary of the Birth of Sakichi Toyoda
- The Chaku Chaku Line
- How to Determine Your Lot Size – Part 3
- How to Determine Your Lot Size – Part 2
- How to Determine Your Lot Size – Part 1
- The Lean Bucket Brigade – Part 2: Details and Caveats
- The Lean Bucket Brigade – Part 1: Overview
- Dealing with Uncertainty
- How to Ramp Up a Kanban System – Part 2: The Switch
- How to Ramp Up a Kanban System – Part 1: Preparation
- Kanban Card Design
- Interview on the David Pakman Show on the Future of Manufacturing
- Line Layout Strategies – Part 3: Merging
- Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines
- Line Layout Strategies – Part 1: The Big Picture
- Loss of Material: Theft!
- Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!
- Toyota’s and Denso’s Relentless Quest for Lot Size One
- “Lean Standard” ISO 18404 – A Questionable Idea …
- Volkswagen Supplier Relations Failure
- Can you tell your Bottleneck from your Inventory?
- The Many Different Flavors of the OEE
- AllAboutLean.com Is Now 3 Years Old! Happy Birthday!
- The History of Manufacturing – Part 4: Toyota and Lean
- The History of Manufacturing – Part 3: Luddism to Henry Ford
- The History of Manufacturing – Part 2: Middle Ages to Industrial Revolution
- The History of Manufacturing – Part 1: Prehistory to Antiquity
- Good and Bad Ways to Calculate the OEE
- How to Prioritize Your Work Orders – Prioritization of Made to Order
- How to Prioritize Your Work Orders – Prioritization of Made to Stock
- How to Prioritize Your Work Orders – The VIP Lane
- How to Prioritize Your Work Orders – Basics
- How to Make “Just in Time” Work – Part 2
- How to Make “Just in Time” Work – Part 1
- What Is “Just in Time”?
- Tales from Japan – Lean in the Japanese Public Toilet
- How Product Variants Influence Your Inventory
- The Relation between Inventory, Customer Takt, and Replenishment Time
- Using Lots of Effort and Money to Demotivate Your People
- The Curious Case of 100% Work Performance
- How Operators Hide the True Workload
- The Many Flavors of the PDCA
- Common Mistakes with the PDCA (and Some History)
- The Key to Lean – Plan, Do, Check, Act!
- Supermarket vs. FiFo – What Requires Less Inventory?
- The A3 Report – Part 3: Limitations and Common Mistakes
- The A3 Report – Part 2: Content
- The A3 Report – Part 1: Basics
- On the Benefits of a Pencil in Lean
- Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu
- Line Balancing Part 6 – Tips and Tricks for Balancing
- Line Balancing Part 5 – Balancing Using Paper
- Line Balancing Part 4 – OEE Usage and Flexibility
- Line Balancing Part 3 – OEE Caveats
- Line Balancing Part 2 – Duration of Tasks
- Line Balancing Part 1 – Data Overview
- The Challenges of Lean Administration
- The Problems of Cost Accounting with Lean
- Taiichi Ohno’s Chalk Circle
- A Critical Look at Industry 4.0
- Lean for Refugees
- How to Reduce Your Inventory
- Why Do We Have Inventory?
- American Automotive Market Strategy of Toyota and Others
- What Is Your Production Capacity?
- How to Use an Andon – and How Not To
- All About Andon
- The Three Fundamental Ways to Decouple Fluctuations
- Pay Attention to Details – Operator Training at Toyota and Scania
- Cycle Times for Manual Processes
- How to Measure Cycle Times – Part 2
- How to Measure Cycle Times – Part 1
- Pitfalls of Takt Times
- How to determine Takt Times
- On the Different Ways to Measure Production Speed
- All About Swim Lane Diagrams
- 2nd Birthday of AllAboutLean.com
- All About Spaghetti Diagrams
- Practical Tips for Value Stream Mapping
- Basics of Value Stream Maps
- Overview of Value Stream Mapping Symbols
- When to Do Value Stream Maps (and When Not!)
- Bubble Diagrams to Visualize Material Flow
- Visualize Your System – Overview of Diagrams in Manufacturing
- 230 Years of Interchangeable Parts – A Brief History
- A Eulogy for Little’s Law
- Theory and Practice of Supermarkets – Part 2
- Theory and Practice of Supermarkets – Part 1
- Why Pull Is So Great!
- The (True) Difference Between Push and Pull
- Twenty-five Years after Ohno – A Look Back
- How to Find a Good Lean Consultant
- Definition of Lean Production
- How to Make 5S Stick
- How 5S Works
- Muda, Mura, Muri: The Three Evils of Manufacturing
- More On Cuba’s Planned Economy: Cuban Industry
- Lies, Damned Lies, and KPI – Part 3 Countermeasures
- Lies, Damned Lies, and KPI – Part 2: Effects of Fudging
- 100th Anniversary of the Death of Frederick Winslow Taylor, the Father of Modern Scientific Management
- Lies, Damned Lies, and KPI – Part 1: Examples of Fudging
- The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
- How a Planned Economy Can Screw Up an Entire Country – Analogy between Cuba’s Communist Economy and Push Systems
- Benefits and Flaws of CONWIP in Comparison to Kanban
- Frequently Asked Questions on CONWIP Systems – Part 2
- Frequently Asked Questions on CONWIP Systems – Part 1
- Basics of CONWIP Systems (Constant Work in Progress)
- Shop Floor Etiquette – Part 2
- Shop Floor Etiquette – Part 1
- Introduction to One-Piece Flow Leveling – Part 2 Implementation
- Introduction to One-Piece Flow Leveling – Part 1 Theory
- The Folly of EPEI Leveling in Practice – Part 2
- The Folly of EPEI Leveling in Practice – Part 1
- Theory of Every Part Every Interval (EPEI) Leveling & Heijunka
- An Introduction to Capacity Leveling
- Why Leveling (Heijunka) is important
- A Critical Look at Goldratt’s Drum-Buffer-Rope Method
- Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
- Bottleneck Management Part 2 – Improve Bottleneck Planning
- Bottleneck Management Part 1 – Introduction and Utilization
- Common Mistakes of Top Executives – A look at “Undercover Boss”
- Top Five Cases When NOT to Use a FiFo
- Eight Rules for Total Gridlock in the Organization (Video)
- A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)
- A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)
- The Advantage of Handwritten Data on the Shop Floor
- The FiFo Calculator – Determining the Size of your Buffers
- Visual Management during World War II – A Visit to the Lascaris War Rooms in Malta
- Happy 1st Birthday AllAboutLean.com
- Determining the Size of Your FiFo Lane – The FiFo Formula
- Theory and Practice on FiFo Lanes – How Does FiFo Work in Lean Manufacturing?
- Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness
- Facing Change in Modern Manufacturing Systems – The Difference between Flexible, Agile, Reconfigurable, Robust, and Adaptable Manufacturing Systems
- The Hidden and not-so-hidden costs of Inventory
- Manufacturing – A key stepping stone on the Road to Prosperity
- The Bottleneck Walk – Practical Bottleneck Detection Part 2
- The Bottleneck Walk – Practical Bottleneck Detection Part 1
- Mathematically Accurate Bottleneck Detection 2 – The Active Period Method
- Mathematically Accurate Bottleneck Detection 1 – The Average Active Period Method
- Common Bottleneck Detection Methods that do NOT work!
- About Shifting Bottlenecks
- Culture of Quality – A Comparison of Toyota and GM Recalls
- Toyota Employee Relationship Crisis and Countermeasures 1990’s
- How Many Kanbans? – Estimation Approach and Maintenance
- How Many Kanbans? – The Kanban Formula, Part 2
- How Many Kanbans? – The Kanban Formula, Part 1
- Cost of Complexity
- The Problem of Losing Kanban – Different Kanban Types
- The Difference Between Lean and Six Sigma
- A Lean Obituary for Maybach – A Cautionary Tale About Cost of Complexity
- How to Manage Your Lean Projects – Prioritize
- How to Manage Your Lean Projects – Number of Active Projects
- How a Little Bit of Industrial Espionage Started the Industrial Revolution
- SMED – Creative Quick Changeover Exercises and Training
- The History of Quick Changeover (SMED)
- Quick Changeover Basics – SMED
- Poka Yoke Training – Simple Mistake Proofing Game
- Dress for Success in Lean Manufacturing
- Shigeo Shingo and the Art of Self Promotion
- Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant
- Lean is Zero Defects? – I don’t think so!
- Consistency at Toyota – The Board of Directors of the Toyota Motor Company
- Japanese Standard Pointing and Calling (Video)
- Value Stream Mapping – Why to Start at the Customer Side
- Simple Triangle Kanban System for Office Supplies
- Ten Rules When to Use a FIFO, When a Supermarket – The Rules
- Ten Rules When to Use a FIFO, When a Supermarket – Introduction
- Hell is Other People – Workplace Conflict between Managers and the Managed
- Internal Threat to the Toyota Production System Due to New Hiring Practices
- Extended Lean Tool Kit for Shop Floor Improvement Projects
- The Tale of Taylor and Gilbreth
- Know Your Priorities!
- Seven Gadgets for the Basic Lean Toolkit
- Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory
- Japanese Multidimensional Problem Solving
- Lean Where You Least Expect It – Toilet Paper Origami
- How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!
- Make Your Plant Tour a Success!
- Visit to Euromold for the Latest in 3D Printing
- Ancient Roman Management Techniques
- What the OEE is Good for … and What it’s Not
- Top Three Methods on how to Fudge Your OEE
- How to Measure OEE
- What is OEE? – Definition of OEE
- New Professor, New Blog
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