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

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