One popular and well-known concept of the Toyota Production System is the elimination of waste, in Japanese also called muda (無駄). It is one of the three evils of manufacturing systems, the others being unevenness (mura, 斑) and overburden (muri, 無理). In this post I would like to go through the details of waste with you. This includes the traditional seven types of waste – of which I am a big fan. For completeness sake I also included a lot more types of waste I have come across in industry. However, you have to decide yourself if these additional wastes are not themselves a waste. Continue reading The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
Bottleneck detection and management are important in managing or increasing your production capacity. In the first post of this series I talked about fundamentals and improving utilization. The second post looked at the impact of planning on the overall production capacity. This final post in the series will look at the effect of decoupling and the actual process capacity improvement. Continue reading Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
Bottleneck detection and management are important when managing or increasing your production capacity. In the first post of this series, I talked about fundamentals and improving utilization. This second post looks at the impact of planning on the overall production capacity. A third post looks at Bottleneck Decoupling and Capacity Improvement. Continue reading Bottleneck Management Part 2 – Improve Bottleneck Planning
In the past I’ve written a few posts with some nifty methods on how to find the bottleneck (The Bottleneck Walk – Practical Bottleneck and The Active Period Method), and some warnings of which methods don’t work. In this post I would like to go into more detail on what to do once you find the bottleneck! Due to the length of this topic, I have split it into multiple posts. This first post gives an introduction and goes into more detail about increasing utilization. The next post talks about planning. A third post looks at Bottleneck Decoupling and Capacity Improvement. Continue reading Bottleneck Management Part 1 – Introduction and Utilization
One popular approach to battle waste is to streamline changeovers. Changing machines from one set-up to another is often a time-consuming exercise. Hence, in lean manufacturing, reducing changeover times is a well-known method for improving efficiency. In this post, we will go through the basic approach of improving changeover time, also known as quick changeover or single minute exchange of die (SMED). Continue reading Quick Changeover Basics – SMED
The Overall Equipment Effectiveness (OEE) is by far and wide the most lied-about and fudged measurement on the shop floor, both intentionally or by accident. This post tells you the top three different ways how an OEE is fudged, so you know which OEE to trust and which one not. Continue reading Top Three Methods on how to Fudge Your OEE
OEE, the abbreviation for Overall Equipment Effectiveness (or sometimes Overall Equipment Efficiency), is a measure of the utilization of a machine. It is frequently used on the shop floor, often determines part of the performance-based compensation of the managers, and is by far and wide the most lied-about and fudged measurement on the shop floor. Continue reading What is OEE? – Definition of OEE