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Archive of All Posts:

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

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