All Posts and Pages

Archive of All Posts:

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

Archive of All Pages:

  1. “Faster, Better, Cheaper” in the History of Manufacturing
  2. About
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  4. All Tags and Categories
  5. Ask me a Question!
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  9. Fertigungstechnik für Führungskräfte
  10. Glossary of Lean Production Related Terms
  11. Professor Dr. Christoph Roser
  12. Publications and Presentations
  13. Services
  14. Some Legalese (Impressum)

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