The Bottleneck Walk – Practical Bottleneck Detection Part 2

Six empty green wine bottlesThe bottleneck walk is far and wide my most favorite method to detect bottlenecks on the shop floor (not only because it was developed by me, but also because it is really good!). You can detect shifting bottlenecks, using no math whatsoever and no time measurements, simply by walking along the production line and observing the line. It’s almost too easy to believe, but it works like a charm! Due to the length of this topic, I have broken the article into two posts. The first post “The Bottleneck Walk – Practical Bottleneck Detection Part 1” details how to find the current temporary bottleneck. This second post details how to determine the big picture regarding the bottlenecks. See below for a complete list of posts on this series on bottlenecks. 

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The Bottleneck Walk – Practical Bottleneck Detection Part 1

Five empty green wine bottlesThe bottleneck walk is far and wide my most favorite method to detect bottlenecks on the shop floor (not only because it was developed by me, but also because it is really good!). You can detect shifting bottlenecks, using no math whatsoever and no time measurements, simply by walking along the production line and observing the line. It’s almost too easy to believe, but it works like a charm! Due to the length of this topic, I have broken the article into two posts. This first post details how to find the current temporary bottleneck. The second post details how to determine the big picture regarding the bottlenecks. See below for a complete list of posts on this series on bottlenecks. 

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Toyota Employee Relationship Crisis and Countermeasures 1990’s

Employee Relations at ToyotaToyota 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.

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Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant

Current Layout of Toyota Motomachi PlantToyota is a company that is constantly evolving, aiming to reduce waste. Over the last few years, I have heard about changes to the Toyota assembly lines to improve efficiency.  During a recent trip to Japan, I was able to observe the assembly line at the Motomachi plant. In this post I will show the evolution of line layouts at Toyota.

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Ten Rules When to Use a FIFO, When a Supermarket – The Rules

Information Loop
FIFO vs. Supermarket

Lean manufacturing pull systems use both FIFO lanes and supermarkets to manage the material and information flow. In my previous post we covered the basics about supermarket and FIFO lanes. Now we go into details about the ten rules when to use a supermarket instead of a FIFO.

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Ten Rules When to Use a FIFO, When a Supermarket – Introduction

Information Loop
FIFO vs. Supermarket

It is generally accepted knowledge that a lean manufacturing pull system uses both FIFO lanes and supermarkets to manage the material and information flow. However, there are few guidelines on when to use a supermarket and when to use a FIFO lane. This post is the first of a two-part series that will give ten general rules of thumb for when to use a supermarket instead of a  FIFO lane. The second post will go into more detail about the ten rules.

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