Management - AllAboutLean.com

Shop Floor Etiquette – Part 1

August 21, 2025January 18, 2015 by Christoph Roser

Greeting — A little courtesy often goes a long way!

There is often a distinct lack of appreciation and good manners toward shop floor employees. Yet, lean manufacturing happens on the shop floor. Not in Excel, not in PowerPoint, not in meeting rooms. As such, you need to become part of the shop floor in order to change the shop floor. For this, you need the support and goodwill of the people on the shop floor. The first step to getting their support is to have good shop floor manners. Due to the length of the post, I have divided it into two posts. These two posts will give you some guidelines on how to behave on the shop floor. (The second post is here)

A Critical Look at Goldratt’s Drum-Buffer-Rope Method

August 21, 2025November 23, 2014 by Christoph Roser

Eliyahu Goldratt developed different methods on how to manage production systems. These methods are nowadays known as the Theory of Constraints, or TOC for short. One key method described is called Drum-Buffer-Rope, or DBM for short. Similar to Kanban or CONWIP, it aims to constrain the work in progress (WIP) in the system. There is much discussion on which method is better than the other, although the result often depends heavily on with which method the respective author earns its living. In this post I will present how Drum-Buffer-Rope works, and discuss its advantages and shortcomings.

Common Mistakes of Top Executives – A look at “Undercover Boss”

August 21, 2025October 26, 2014 by Christoph Roser

I occasionally watch the reality show Undercover Boss, where top executives work undercover in their own companies. Over and over again I see these managers making the same mistake: They have no understanding whatsoever of what is really happening on the front lines. It is a typical case of not going to the shop floor often enough, or in lean speak, no genchi genbutsu (Japanese for “go and see”). So, <dramatic voice> Why do bosses all make the same mistake? Will they ever learn? Will you enjoy this post? See for yourself in the post below! </dramatic voice>.

Eight Rules for Total Gridlock in the Organization (Video)

August 21, 2025October 12, 2014 by Christoph Roser

There is an excellent and highly sarcastic video around by Prof. Dr. Peter Kruse, professor of organizational psychology at the University of Bremen. In this, he describes his Eight Rules for Total Gridlock in the Organization (8 Regeln für den totalen Stillstand). Since these eight rules are quite relevant to the lean change process, I have transcribed, translated, and subtitled the German video for you into English.

A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)

August 21, 2025October 5, 2014 by Christoph Roser

Half a century ago, Toyota started to develop its Toyota Production System, the archetype of every lean manufacturing system. Almost every manufacturing company nowadays seems to try to implement lean manufacturing. At the same time, most also seem to fail miserably, creating a lot of huff and puff with little benefit. However, occasionally there are (very) few companies that have implemented lean manufacturing successfully. Trumpf and its Synchro production system is such a successful example of Lean manufacturing, and one of the finest production system for machine tool builders. Due to the length I have split this post into two parts. This is the second part.

A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)

August 21, 2025September 28, 2014 by Christoph Roser

Almost a century ago, Toyota started to develop its Toyota Production System, the archetype of every lean manufacturing system. Almost every manufacturing company nowadays seems to try to implement lean manufacturing. At the same time, most also seem to fail miserably, creating a lot of huff and puff with little benefit. However, occasionally there are (very) few companies that have implemented lean manufacturing successfully. Trumpf and its Synchro production system is such a successful example of Lean manufacturing, and one of the finest production system for machine tool builders. Due to the length I have split this post into two parts, the second part being available here.

Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness

December 13, 2025August 10, 2014 by Christoph Roser

Quality starts at the top with management. Top executives like to talk about quality, but employees below usually know very well if the manager only talks the talk or also walks the walk. Words are cheap. Quality (and pretty much everything else that is important) requires attention by management.

Toyota Employee Relationship Crisis and Countermeasures 1990’s

December 13, 2025May 25, 2014 by Christoph Roser

Toyota has developed what is probably the finest production system in the world, the Toyota Production System. There is general consensus in the rest of the world that its methods and philosophies can significantly improve efficiency and quality, to the point that anything Toyota does is admired and copied. Some practitioners seem to wear rose-colored glasses when talking about Toyota. However, like any company, Toyota does have its fair share of problems and mishaps to deal with, from the 1950 near collapse, to the US gas pedal recalls during 2009–2011. This post will discuss the employee relationship crisis at Toyota around 1990 and Toyota’s countermeasures.