All Posts and Pages

Archive of All Posts:

  1. Introduction to Point-of-Use Providers (or Mizusumashi)
  2. Lean Construction
  3. Example of Problem Solving – Japanese Men’s Relay Team Rio 2016
  4. A Good Standard Needs No Explanation
  5. External Milk Runs
  6. Frequently Asked Questions for Milk Runs
  7. Milk Run Layout
  8. Calculating the Material for Your Milk Run
  9. Milk Run Basics
  10. Introduction to Milk Runs
  11. Just in Time at Hyundai Mobis in Korea
  12. Toyota Kata
  13. Happy 5th Birthday AllAboutLean.com
  14. Calculating the Number of POLCA Cards
  15. Advantages and Disadvantages of POLCA
  16. What Is POLCA?
  17. Lean and Industry 4.0
  18. Examples of Jidoka
  19. The Philosophy and Practicality of Jidoka
  20. What Exactly Is Jidoka?
  21. All About 5 Why
  22. Toyota Standard Work – Part 3: Standard Work Layout
  23. Toyota Standard Work – Part 2: Standard Work Combination Table
  24. Toyota Standard Work – Part 1: Production Capacity
  25. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 2
  26. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 1
  27. My Workshop Structure for Creative Problem Solving
  28. Creative Provocation, Reverse Brainstorming, and Analogy
  29. Fishbone Diagrams and Mind Maps
  30. How to Do Brainstorming
  31. Leading with Confidence
  32. Effect of Prioritization on Waiting Times
  33. The Grand Tour of Japanese Automotive – Subaru
  34. The Grand Tour of Japanese Automotive – Suzuki
  35. The Grand Tour of Japanese Automotive – Mazda
  36. The Grand Tour of Japanese Automotive – Mitsubishi
  37. The Grand Tour of Japanese Automotive – Honda Kumamoto
  38. The Grand Tour of Japanese Automotive – Honda Sayama
  39. The Grand Tour of Japanese Automotive – Nissan
  40. The Grand Tour of Japanese Automotive – Overview and Toyota
  41. Continued Evolution of the Toyota Assembly Line
  42. More on TWI Programs
  43. JM: Training within Industry – Job Methods
  44. JR: Training within Industry – Job Relations
  45. JI: Training within Industry – Job Instructions
  46. Training within Industry – TWI – Oldies but Goldies
  47. Heroes, Firefighting, and Corporate Culture
  48. The Dark Side of Japanese Working Society
  49. The Toyota Employee Evaluation System
  50. Anatomy of the Toyota Kanban
  51. Monozukuri – Japanese Work Ethics
  52. A Small Dice Game for the Kingman Formula
  53. Twelve Ways to Create Space around Your Assembly – Part 2
  54. Twelve Ways to Create Space around Your Assembly – Part 1
  55. Structured Approach to Material Supply for Assembly – Part 2
  56. Structured Approach to Material Supply for Assembly – Part 1
  57. The Challenges of Material Supply for Assembly
  58. Karakuri Kaizen Examples
  59. Fundamentals of Karakuri Kaizen
  60. Introduction to Karakuri Kaizen
  61. Industry 4.0 – What Works, What Doesn’t
  62. How to Deal With Long Delivery Times
  63. The Kingman Formula – Variation, Utilization, and Lead Time
  64. Ship to Line
  65. Happy 4th Birthday AllAboutLean.com
  66. Just in Sequence Part 3 – What Can Go Wrong
  67. Just in Sequence Part 2 – How to Do It
  68. Just in Sequence Part 1 – What Is It?
  69. Different Ways to Establish a Pull System – Part 2
  70. Different Ways to Establish a Pull System – Part 1
  71. Visual Management
  72. Employee Motivation and Lean Implementation – Part 4: Respect for People
  73. Employee Motivation and Lean Implementation – Part 3: Lack of Respect
  74. Employee Motivation and Lean Implementation – Part 2: Money
  75. Employee Motivation and Lean Implementation – Part 1: Carrot and Stick
  76. Changeover Sequencing – Part 2
  77. Changeover Sequencing – Part 1
  78. On Running Changeovers
  79. The Phases of a Changeover
  80. What to Do with SMED: Reduce Lot Size or Increase Work Time?
  81. Where Lean Went Wrong – A Historical Perspective
  82. Strategies for Mass Customization
  83. Material Flow in the Arsenal of Venice 1797
  84. The Arsenal of Venice
  85. Pacing of Flow Lines 2 – Continuously Moving Line
  86. Pacing of Flow Lines 1 – Unstructured and Pulse Line
  87. Lean Is Tough – The Phases of a Lean Transformation
  88. Organize Your Production Sequence – 3: Flow Shop
  89. Organize Your Production Sequence – 2: Job Shop
  90. Organize Your Production Sequence – 1: Project Shop
  91. The Lean Mindset – Te & Kaffi in Iceland
  92. Lean Tales in Japan: The Japanese Supermarket Checkout
  93. The Lean Rabbit Chase in a U-Line
  94. 150th Anniversary of the Birth of Sakichi Toyoda
  95. The Chaku Chaku Line
  96. How to Determine Your Lot Size – Part 3
  97. How to Determine Your Lot Size – Part 2
  98. How to Determine Your Lot Size – Part 1
  99. The Lean Bucket Brigade – Part 2: Details and Caveats
  100. The Lean Bucket Brigade – Part 1: Overview
  101. Dealing with Uncertainty
  102. How to Ramp Up a Kanban System – Part 2: The Switch
  103. How to Ramp Up a Kanban System – Part 1: Preparation
  104. Kanban Card Design
  105. Interview on the David Pakman Show on the Future of Manufacturing
  106. Line Layout Strategies – Part 3: Merging
  107. Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines
  108. Line Layout Strategies – Part 1: The Big Picture
  109. Loss of Material: Theft!
  110. Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!
  111. Toyota’s and Denso’s Relentless Quest for Lot Size One
  112. “Lean Standard” ISO 18404 – A Questionable Idea …
  113. Volkswagen Supplier Relations Failure
  114. Can you tell your Bottleneck from your Inventory?
  115. The Many Different Flavors of the OEE
  116. AllAboutLean.com Is Now 3 Years Old! Happy Birthday!
  117. The History of Manufacturing – Part 4: Toyota and Lean
  118. The History of Manufacturing – Part 3: Luddism to Henry Ford
  119. The History of Manufacturing – Part 2: Middle Ages to Industrial Revolution
  120. The History of Manufacturing – Part 1: Prehistory to Antiquity
  121. Good and Bad Ways to Calculate the OEE
  122. How to Prioritize Your Work Orders – Prioritization of Made to Order
  123. How to Prioritize Your Work Orders – Prioritization of Made to Stock
  124. How to Prioritize Your Work Orders – The VIP Lane
  125. How to Prioritize Your Work Orders – Basics
  126. How to Make “Just in Time” Work – Part 2
  127. How to Make “Just in Time” Work – Part 1
  128. What Is “Just in Time”?
  129. Tales from Japan – Lean in the Japanese Public Toilet
  130. How Product Variants Influence Your Inventory
  131. The Relation between Inventory, Customer Takt, and Replenishment Time
  132. Using Lots of Effort and Money to Demotivate Your People
  133. The Curious Case of 100% Work Performance
  134. How Operators Hide the True Workload
  135. The Many Flavors of the PDCA
  136. Common Mistakes with the PDCA (and Some History)
  137. The Key to Lean – Plan, Do, Check, Act!
  138. Supermarket vs. FiFo – What Requires Less Inventory?
  139. The A3 Report – Part 3: Limitations and Common Mistakes
  140. The A3 Report – Part 2: Content
  141. The A3 Report – Part 1: Basics
  142. On the Benefits of a Pencil in Lean
  143. Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu
  144. Line Balancing Part 6 – Tips and Tricks for Balancing
  145. Line Balancing Part 5 – Balancing Using Paper
  146. Line Balancing Part 4 – OEE Usage and Flexibility
  147. Line Balancing Part 3 – OEE Caveats
  148. Line Balancing Part 2 – Duration of Tasks
  149. Line Balancing Part 1 – Data Overview
  150. The Challenges of Lean Administration
  151. The Problems of Cost Accounting with Lean
  152. Taiichi Ohno’s Chalk Circle
  153. A Critical Look at Industry 4.0
  154. Lean for Refugees
  155. How to Reduce Your Inventory
  156. Why Do We Have Inventory?
  157. American Automotive Market Strategy of Toyota and Others
  158. What Is Your Production Capacity?
  159. How to Use an Andon – and How Not To
  160. All About Andon
  161. The Three Fundamental Ways to Decouple Fluctuations
  162. Pay Attention to Details – Operator Training at Toyota and Scania
  163. Cycle Times for Manual Processes
  164. How to Measure Cycle Times – Part 2
  165. How to Measure Cycle Times – Part 1
  166. Pitfalls of Takt Times
  167. How to determine Takt Times
  168. On the Different Ways to Measure Production Speed
  169. All About Swim Lane Diagrams
  170. 2nd Birthday of AllAboutLean.com
  171. All About Spaghetti Diagrams
  172. Practical Tips for Value Stream Mapping
  173. Basics of Value Stream Maps
  174. Overview of Value Stream Mapping Symbols
  175. When to Do Value Stream Maps (and When Not!)
  176. Bubble Diagrams to Visualize Material Flow
  177. Visualize Your System – Overview of Diagrams in Manufacturing
  178. 230 Years of Interchangeable Parts – A Brief History
  179. A Eulogy for Little’s Law
  180. Theory and Practice of Supermarkets – Part 2
  181. Theory and Practice of Supermarkets – Part 1
  182. Why Pull Is So Great!
  183. The (True) Difference Between Push and Pull
  184. Twenty-five Years after Ohno – A Look Back
  185. How to Find a Good Lean Consultant
  186. Definition of Lean Production
  187. How to Make 5S Stick
  188. How 5S Works
  189. Muda, Mura, Muri: The Three Evils of Manufacturing
  190. More On Cuba’s Planned Economy: Cuban Industry
  191. Lies, Damned Lies, and KPI – Part 3 Countermeasures
  192. Lies, Damned Lies, and KPI – Part 2: Effects of Fudging
  193. 100th Anniversary of the Death of Frederick Winslow Taylor, the Father of Modern Scientific Management
  194. Lies, Damned Lies, and KPI – Part 1: Examples of Fudging
  195. The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
  196. How a Planned Economy Can Screw Up an Entire Country – Analogy between Cuba’s Communist Economy and Push Systems
  197. Benefits and Flaws of CONWIP in Comparison to Kanban
  198. Frequently Asked Questions on CONWIP Systems – Part 2
  199. Frequently Asked Questions on CONWIP Systems – Part 1
  200. Basics of CONWIP Systems (Constant Work in Progress)
  201. Shop Floor Etiquette – Part 2
  202. Shop Floor Etiquette – Part 1
  203. Introduction to One-Piece Flow Leveling – Part 2 Implementation
  204. Introduction to One-Piece Flow Leveling – Part 1 Theory
  205. The Folly of EPEI Leveling in Practice – Part 2
  206. The Folly of EPEI Leveling in Practice – Part 1
  207. Theory of Every Part Every Interval (EPEI) Leveling & Heijunka
  208. An Introduction to Capacity Leveling
  209. Why Leveling (Heijunka) is important
  210. A Critical Look at Goldratt’s Drum-Buffer-Rope Method
  211. Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
  212. Bottleneck Management Part 2 – Improve Bottleneck Planning
  213. Bottleneck Management Part 1 – Introduction and Utilization
  214. Common Mistakes of Top Executives – A look at “Undercover Boss”
  215. Top Five Cases When NOT to Use a FiFo
  216. Eight Rules for Total Gridlock in the Organization (Video)
  217. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)
  218. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)
  219. The Advantage of Handwritten Data on the Shop Floor
  220. The FiFo Calculator – Determining the Size of your Buffers
  221. Visual Management during World War II – A Visit to the Lascaris War Rooms in Malta
  222. Happy 1st Birthday AllAboutLean.com
  223. Determining the Size of Your FiFo Lane – The FiFo Formula
  224. Theory and Practice on FiFo Lanes – How Does FiFo Work in Lean Manufacturing?
  225. Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness
  226. Facing Change in Modern Manufacturing Systems – The Difference between Flexible, Agile, Reconfigurable, Robust, and Adaptable Manufacturing Systems
  227. The Hidden and not-so-hidden costs of Inventory
  228. Manufacturing – A key stepping stone on the Road to Prosperity
  229. The Bottleneck Walk – Practical Bottleneck Detection Part 2
  230. The Bottleneck Walk – Practical Bottleneck Detection Part 1
  231. Mathematically Accurate Bottleneck Detection 2 – The Active Period Method
  232. Mathematically Accurate Bottleneck Detection 1 – The Average Active Period Method
  233. Common Bottleneck Detection Methods that do NOT work!
  234. About Shifting Bottlenecks
  235. Culture of Quality – A Comparison of Toyota and GM Recalls
  236. Toyota Employee Relationship Crisis and Countermeasures 1990’s
  237. How Many Kanbans? – Estimation Approach and Maintenance
  238. How Many Kanbans? – The Kanban Formula, Part 2
  239. How Many Kanbans? – The Kanban Formula, Part 1
  240. Cost of Complexity
  241. The Problem of Losing Kanban – Different Kanban Types
  242. The Difference Between Lean and Six Sigma
  243. A Lean Obituary for Maybach – A Cautionary Tale About Cost of Complexity
  244. How to Manage Your Lean Projects – Prioritize
  245. How to Manage Your Lean Projects – Number of Active Projects
  246. How a Little Bit of Industrial Espionage Started the Industrial Revolution
  247. SMED – Creative Quick Changeover Exercises and Training
  248. The History of Quick Changeover (SMED)
  249. Quick Changeover Basics – SMED
  250. Poka Yoke Training – Simple Mistake Proofing Game
  251. Dress for Success in Lean Manufacturing
  252. Shigeo Shingo and the Art of Self Promotion
  253. Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant
  254. Lean is Zero Defects? – I don’t think so!
  255. Consistency at Toyota – The Board of Directors of the Toyota Motor Company
  256. Japanese Standard Pointing and Calling (Video)
  257. Value Stream Mapping – Why to Start at the Customer Side
  258. Simple Triangle Kanban System for Office Supplies
  259. Ten Rules When to Use a FIFO, When a Supermarket – The Rules
  260. Ten Rules When to Use a FIFO, When a Supermarket – Introduction
  261. Hell is Other People – Workplace Conflict between Managers and the Managed
  262. Internal Threat to the Toyota Production System Due to New Hiring Practices
  263. Extended Lean Tool Kit for Shop Floor Improvement Projects
  264. The Tale of Taylor and Gilbreth
  265. Know Your Priorities!
  266. Seven Gadgets for the Basic Lean Toolkit
  267. Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory
  268. Japanese Multidimensional Problem Solving
  269. Lean Where You Least Expect It – Toilet Paper Origami
  270. How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!
  271. Make Your Plant Tour a Success!
  272. Visit to Euromold for the Latest in 3D Printing
  273. Ancient Roman Management Techniques
  274. What the OEE is Good for … and What it’s Not
  275. Top Three Methods on how to Fudge Your OEE
  276. How to Measure OEE
  277. What is OEE? – Definition of OEE
  278. New Professor, New Blog

Archive of All Pages:

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