Category Archives: Practical Tips

Hands on, practical tips that you can use for your work immediately. Academic theory is reduced to a minimum

Maintaining Weak FIFO in Parallel FIFO Lanes

Sometimes you would like to put more material in a single FIFO lane than the space you have available. In this case you would have to use a combination of two or more parallel FIFO lanes. In my last post I described how to maintain a strict FIFO sequence in parallel lanes. This post looks at an easier but less accurate method. Continue reading Maintaining Weak FIFO in Parallel FIFO Lanes

My Workshop Structure for Creative Problem Solving

In lean manufacturing – or in fact, in any kind of production system – you have to solve problems. Depending on the problem, you may need a creative solution and have to access the wisdom of the crowd. For this I have a workshop structure that I frequently use for problems that have lots of different options. Let me show you my workshop structure with which I’ve had quite good results. Continue reading My Workshop Structure for Creative Problem Solving

Visual Management

Yet another hot topic in lean manufacturing is visual management. This can be very helpful in running a shop floor, but when done wrong it can also be quite wasteful and embarrassing. In this post I would like to show you the basic principles of visual management with a few examples. There is more to visual management than merely putting lines on the shop floor.  Continue reading Visual Management

How to Ramp Up a Kanban System – Part 2: The Switch

fotolia_on-air_trimmedIn my last post I described how to prepare for the implementation of a kanban system. This post goes into more detail on the actual change to the new kanban system. You surely know that every part should have a kanban. But what do you do if you have more kanban than parts? What do you do if you have more parts than kanbans? Find the answers below. Continue reading How to Ramp Up a Kanban System – Part 2: The Switch

How to Ramp Up a Kanban System – Part 1: Preparation

Simple Kanban LoopDesigning a kanban system on paper is much easier than implementing it on the shop floor. In many of my previous posts I discussed the design of a kanban system in detail. In these two posts I will discuss the steps needed to actually put the system on the ground.  This first post is the preparation, and my next post will be the actual switch to the new kanban system. Continue reading How to Ramp Up a Kanban System – Part 1: Preparation

Kanban Card Design

kanban-card-pileA kanban is, in its basics, information to reproduce or reorder parts. Hence, in its most basic form it has to say “make me this part” or “bring me this part.” While such very simple kanban systems are possible, usually it helps to include other information on the kanban card. In this post I want to talk about the design details of a kanban card, especially what kind of information we should include on the card. Please note that the items on the list below are suggestions. Which ones you actually include depend on the system you want to establish. Continue reading Kanban Card Design