All Posts and Pages

Archive of All Posts:

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

Archive of All Pages:

1. About
2. All About Pull Production
3. All About Work Standards
4. All Categories and Tags
5. All Posts and Pages
6. Ask me a Question!
7. Awards
8. Collected Blog Posts of AllAboutLean.com
9. Consulting
10. Contact
11. Credits
12. Faster, Better, Cheaper in the History of Manufacturing
13. Fertigungstechnik für Führungskräfte
14. Fertigungstechnik für Führungskräfte – Dritte Ausgabe
15. Fertigungstechnik für Führungskräfte – Erste Ausgabe
16. Fertigungstechnik für Führungskräfte – Zweite Ausgabe
17. Font Samples
18. Glossary of Lean Production Related Terms
19. Impressum (Imprint)
20. Imprint (Impressum) and Privacy Policy
21. Lean Global Network
22. Permission for Translations from AllAboutLean.com
23. Permission to Use Images from AllAboutLean.com
24. Privacy Policy
25. Professor Dr. Christoph Roser
26. Public Speaking
27. Publications and Presentations
28. Trainings
29. Translations of All About Pull Production
30. Translations of All About Work Standards
31. Zusatzmaterial zum Buch “Fertigungstechnik für Führungskräfte”