All Posts and Pages

Archive of All Posts:

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

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