All posts by Christoph Roser

115 Years after the Birth of Joseph Juran

On Christmas Eve 115 years ago, Joseph Moses Juran (December 24, 1904 – February 28, 2008) was born. He was a highly respected and very influential quality guru. His work not only helped the United States, but also changed Japan, possibly even more than that of his better-known colleague Edwards Deming. Time to look back on his life’s impact on the world. Continue reading 115 Years after the Birth of Joseph Juran

When and How to Use Extra Kanban

Dog with bandage and first aid kitKanban (and pull systems in general) are a beautiful way to manage production. While the number of kanban cards should be verified periodically, for certain situations, however, it may be sensible to have additional kanban prepared. These extra kanban are added to the system on short notice to alleviate symptoms of other problems. However, please do not see this as a new and cool additional feature to your kanban system. Instead, if you have to use extra kanban, then something is going  wrong. Such extra kanban are only an emergency fix and do not solve the underlying problem. Still, in some cases you do need an emergency fix. Let me explain: Continue reading When and How to Use Extra Kanban

More Reasons for Working Less

You probably hate long drudging hours working in the office and feeling really worn out at the end of the day. Maybe you’re sitting in an office working right now (and of course your reading my blog means you are working 😉 ), knowing that you will be worn out at the end of the day. This post is especially for you, looking at work hours and productivity. The good news is: Less is more, but don’t overdo it! Continue reading More Reasons for Working Less

One Up One Down – Approach to Manage Manual Production Lines

Production lines have fluctuations. Sometimes production takes longer, sometimes shorter, than the average. This makes the line balancing tricky. Besides using a simple buffer between workstations, it is also possible to adjust capacity. Other approaches I have written about include the rabbit chase and the bucket brigade. Here I present a variation of the bucket brigade called “One Up One Down.” Continue reading One Up One Down – Approach to Manage Manual Production Lines

The Inner Workings of Amazon Fulfillment Centers – Part 6

This is the sixth and last post on my series on the inner workings of the Amazon Fulfillment Center. Here I will look at some supporting processes as well as the all-important employee satisfaction. I will look at the process of taking inventory, security, their interesting office locations on the warehouse floor, Amazon Go stores, and Employee Satisfaction.

Continue reading The Inner Workings of Amazon Fulfillment Centers – Part 6

The Inner Workings of Amazon Fulfillment Centers – Part 5

This is the fifth post on my series on the inner workings of the Amazon Fulfillment Center. Here I will look at the software that runs behind all the processes and makes this performance possible. Other companies would probably plaster the label “Industry 4.0” all over this, but at Amazon they just do it.

Continue reading The Inner Workings of Amazon Fulfillment Centers – Part 5

The Inner Workings of Amazon Fulfillment Centers – Part 4

This fourth post in the series on the inner workings of the Amazon Fulfillment Center will continue to look at the outbound material flow, including pack, SLAM, and the loading of the trucks. In the next and last posts, I will also look at the software behind it as well as some surrounding processes.

Continue reading The Inner Workings of Amazon Fulfillment Centers – Part 4

The Inner Workings of Amazon Fulfillment Centers – Part 3

This is the third post on my series on the inner workings of the Amazon Fulfillment Center. In this post I start with the highly interesting process of the outbound value stream (i.e., how the goodies go from storage to your door). Since this is the core process, the next post will continue this outbound value stream.

Continue reading The Inner Workings of Amazon Fulfillment Centers – Part 3