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Archive of All Posts:

  1. The Evolution of Automotive Assembly Line—Part 2
  2. The Evolution of Automotive Assembly Line—Part 1
  3. The BMW Finger Line Layout
  4. Variable Takt at Fendt in Marktoberdorf—Part 3
  5. Variable Takt at Fendt in Marktoberdorf—Part 2
  6. Variable Takt at Fendt in Marktoberdorf—Part 1
  7. Using Empty Slots on the Assembly Line
  8. The Two Directions of Poka Yoke
  9. Different Aspects of Seeing a Shop Floor—Data
  10. Different Aspects of Seeing a Shop Floor—Gemba vs. Data
  11. Different Aspects of Seeing a Shop Floor—Unevenness, Overburden, and Safety
  12. Different Aspects of Seeing a Shop Floor—Visual Management, 5S, and Waste
  13. Different Aspects of Seeing a Shop Floor—Introduction
  14. Luxury Car Assembly at Audi and Daimler
  15. How to Pace Your Assembly Line
  16. Keep Calm and Stop the Line—Part 2
  17. Keep Calm and Stop the Line—Part 1
  18. Toyota Practical Problem Solving (PPS)—Monitor and Share
  19. Toyota Practical Problem Solving (PPS)—Countermeasures and Implement
  20. Toyota Practical Problem Solving (PPS)—Targets and Root Causes
  21. Toyota Practical Problem Solving (PPS)—Clarify
  22. Toyota Practical Problem Solving (PPS)—Introduction
  23. What Exactly Is Overburden (Muri)?
  24. Lessons Learned from the Toyota KPI Dashboard for Your Own Dashboard
  25. The Toyota KPI Dashboard—Production Plan
  26. The Toyota KPI Dashboard—Human Resources
  27. The Toyota KPI Dashboard—Cost
  28. The Toyota KPI Dashboard—Productivity
  29. The Toyota KPI Dashboard—Quality
  30. The Toyota KPI Dashboard—Safety
  31. The Toyota KPI Dashboard—Overview
  32. Dos and Do Nots for KPIs
  33. Ramp-Up and Ramp-Down of Production
  34. Preparation for Ramp Up and Down of Production
  35. Happy 10th Birthday, AllAboutLean.com
  36. When to Use Standards…and When Not
  37. Different Ways to Do Kaizen
  38. The Soft Power of the Toyota Production System—Yokoten, Nemawashi, and More
  39. Continuously Moving Assembly Line—Speed Limitations
  40. Continuously Moving Assembly Line—Special Situations
  41. Continuously Moving Assembly Line—How to Do Line Balancing
  42. Continuously Moving Assembly Line—Speed, Work Content, and Length
  43. The Particularities of Continuously Moving Assembly Lines
  44. How to Do Make-or-Buy
  45. Make or Buy: How Not to Do It
  46. Flexible Multi-Model Assembly Line at Toyota
  47. Training Within Industry—Second-Line Supervisor Job Instructions
  48. Real vs. Planned Data in Pull Systems
  49. The Difference between the Toyota Production System and Lean Manufacturing
  50. KUKA FAMULUS Turns 50—The First Modern Industrial Robot
  51. When to Use a Milk Run
  52. Stack Lights—Visual Management Done Easy
  53. SMED 2.0—A Changeover for the Changeover
  54. The Danger of Management by Numbers
  55. Making the Problem go Away Is NOT Improvement
  56. On the Team Structure at Toyota
  57. Adding Another Axis to the Qualification Matrix—Products
  58. How to Use a Qualification Matrix
  59. How to Establish a Qualification Matrix
  60. On the Benefits of Putting Your Processes Close Together
  61. Steps Toward One-Piece Flow
  62. Akio Toyoda Steps Down as Toyota CEO
  63. What Are the Advantages of One-Piece Flow?
  64. The Impact of ChatGPT on the Future of Work
  65. The Limits of Work Standards
  66. What’s Buzzing?—Vibration Sensors in Industry
  67. The Difficulties of Dazzling Digital Shop Floor Dashboards
  68. Toyota’s New Type of Flexible Assembly Lines—Takaoka Line #2
  69. Omotenashi in Product Design
  70. The Van of Nerds in France—Trains and Cars
  71. The Van of Nerds in France—Internal Logistics in Well Exploration and Military Products
  72. The Van of Nerds in France—Aircraft Engines and Parts
  73. The Van of Nerds in France—Research Laboratories
  74. The Van of Nerds in France—Overview and Aircrafts
  75. Toyota’s Master Craftsmen: Takumi
  76. What Is Ikigai?
  77. How to Reduce Part Variants
  78. How to Reduce Product Variants
  79. How to Reduce Your Lot Size Part 3—Customer, Machine, Leveling, and Tradition
  80. How to Reduce Your Lot Size Part 2—Changeover, Container, and Shipments
  81. How to Reduce Your Lot Size Part 1—Introduction
  82. Why FIFO: The Benefits of First In, First Out
  83. What Should Be Your Target OEE?
  84. Should You Split Your Production System into Two?
  85. This is NOT Lean: Lean Staffing
  86. 250 Years of the Cromford Cotton Mill – Start of the Industrial Revolution
  87. Happy 9th Birthday, AllAboutLean.com
  88. Examples of Job Shop to Flow Shop Conversions
  89. Manufacturing in a War Zone – Part 2
  90. Manufacturing in a War Zone – Part 1
  91. What is One-Piece Flow?
  92. What Is Flow?
  93. How IKEA Uses Drones for Inventory Management
  94. Drones in Manufacturing
  95. The 6R Goals of Lean Manufacturing
  96. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 3
  97. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 2
  98. How to Look Good at the Cost of Your Successor (Please Don’t!)–Part 1
  99. Virtual Reality Factory for Training and Teaching
  100. Where to Start Your Kaizen?
  101. The Modern Way to Buy Screws
  102. The Problem of Industry 4.0: Data! – Part 2
  103. The Problem of Industry 4.0: Data! – Part 1
  104. Evolution of Process Placement at Toyota – Part 2
  105. Evolution of Process Placement at Toyota – Part 1
  106. Material Flow and Traffic Flow – An Analogy
  107. 250 Years after the Birth of Eli Terry
  108. On Standard Tools and Standard Solutions…
  109. 50 Years of SAP–Blessing or a Curse?
  110. How Managers Drove Boeing into the Ground…
  111. A Few More Turns on the Changeover Wheel – Part 5: Frequently Asked Questions
  112. A Few More Turns on the Changeover Wheel – Part 4: Options for Prioritizing
  113. A Few More Turns on the Changeover Wheel – Part 3: Prioritizing Jobs
  114. A Few More Turns on the Changeover Wheel – Part 2: Improving the Sequence
  115. A Few More Turns on the Changeover Wheel – Part 1: Creating a Sequence
  116. AI in Manufacturing: Hype or Helpful?
  117. What Percentage Value Add to Expect for Manual Work?
  118. How to Estimate Value Add for Manual Work – How to See Waste!
  119. On Workplace Safety
  120. Alec Baldwin and Workplace Safety
  121. 50 Years after the Death of Lillian Evelyn Gilbreth
  122. Changeover Sequencing under Duress: Problems with Make and Deliver
  123. Changeover Sequencing under Duress: Problems with Source
  124. The Benefits of Mass Production
  125. Make-to-Order vs Make-to-Stock: Additional Decision Factors
  126. Make-to-Order vs Make-to-Stock: The ABC XYZ Analysis
  127. When to Produce Make-to-Order, When Make-to-Stock?
  128. Replenishment Time Stability for Changeover Sequencing
  129. How to Prioritize in Changeover Sequencing
  130. Can You Plan Around Your Fluctuations?
  131. The Boss Knows Best … or Does He?
  132. Military Leadership and Disobedience
  133. Ten Years of Industry 4.0-Quo Vadis?
  134. Work Improvement before Equipment Improvement
  135. How to Convince Your People to Do a Lean Transformation
  136. About the Value of Disagreement for Leadership
  137. About Just in Time and Fluctuations (Like… a Pandemic…)
  138. Standards Part 9: Leader Standard Work
  139. Happy 8th Birthday AllAboutLean.com
  140. Standards Part 8: Example for a Work Standard
  141. Standards Part 7: How to Write a Work Standard
  142. Standards Part 6: Standardized Work
  143. Standards Part 5: How to Use and Improve a Standard
  144. Standards Part 4: How to Write a Standard (Continued)
  145. Standards Part 3: How to Write a Standard
  146. Standards Part 2: Why and Where to Do Standards
  147. Standards Part 1: What Are Standards?
  148. How Much to Adjust the Pull Inventory Limit
  149. Behavior of a Kanban Supermarket
  150. Performance Comparison of Job Shop and Flow Shop
  151. What Different Pull Systems Can Be Combined?
  152. Which Pull System Is Right for You?
  153. What Are the Criteria to Decide on a Pull System?
  154. The Different Ways to Establish Pull Production
  155. Pull: A Way Forward for Supply Chains – Guest Post by John Shook
  156. An Alternative Structure for Total Productive Maintenance
  157. How to Do Reactive Maintenance
  158. The Pillars of TPM – The Missing Pillar Reactive Maintenance?
  159. The Pillars of TPM – Quality, Training, Administration, and Safety
  160. The Pillars of TPM – Early Equipment Management
  161. The Pillars of TPM – Planned Maintenance
  162. The Pillars of TPM – Autonomous Maintenance
  163. The Pillars of TPM – Focused Improvement
  164. An Overview of the Eight Pillars of Total Productive Maintenance
  165. What Are the Goals of Maintenance?
  166. A Brief History of Maintenance
  167. What Is a Good Minimum for the Supermarket?
  168. How to Use a Minimum in a Supermarket
  169. Manufacturing Drives Prosperity
  170. Respect for People – It’s Difficult…
  171. Respect for People – Why and How
  172. Respect for People – Introduction
  173. Reducing Lead Time 4 – Development
  174. Reducing Lead Time 3 – Throughput and Lot Size
  175. Reducing Lead Time 2 – Fluctuations and Utilization
  176. Reducing Lead Time 1 – Inventory
  177. What Is True North in Lean?
  178. The Baton Touch Flow Line
  179. How to Learn Lean
  180. The Impact of Brexit on Supply Chains
  181. Reducing Fluctuations Downstream
  182. Reducing Fluctuations on Your Shop Floor
  183. Reducing Fluctuations Upstream
  184. Structure for Reducing Fluctuations
  185. Why Are Fluctuations So Bad?
  186. How to Roll Out a Lean Transformation
  187. Key Points for a Lean Transformation
  188. How NOT to Do a Lean Transformation – A Case Study of GM
  189. How to Do a Lean Transformation – The Toyota Approach
  190. When NOT to Balance a Line
  191. Happy 7th Birthday AllAboutLean.com
  192. Toyota’s Six Rules for Kanban
  193. How the Corona Virus affects Logistics
  194. On the Safety of Workers During Corona – Part 2
  195. On the Safety of Workers During Corona – Part 1
  196. Design for X
  197. Design for Assembly Questions – Part 3
  198. Design for Assembly Questions – Part 2
  199. Design for Assembly Questions – Part 1
  200. Design for Manufacturing Questions
  201. Design for Manufacturing and Assembly Workshop Preparation
  202. Design for Manufacturing and Assembly Basics
  203. How to Convert a Job Shop into a Flow Shop – Part 2
  204. How to Convert a Job Shop into a Flow Shop – Part 1
  205. Why Are Job Shops Always Such a Chaotic Mess? Part 2
  206. Why Are Job Shops Always Such a Chaotic Mess? Part 1
  207. How to Conduct a Shop Floor Meeting
  208. How to Set Up a Shop Floor Meeting – Part 2
  209. How to Set Up a Shop Floor Meeting – Part 1
  210. When NOT to Pull!
  211. American Factory – Documentary of a Chinese Automotive Factory in the USA
  212. Fictional Movie on US-Japan Automotive Culture Clash – Gung Ho
  213. The Amazon Robotics Family: Kiva, Pegasus, Xanthus, and more…
  214. Amazon Kiva Storage Strategies
  215. Where Is All the Toilet Paper? Don’t Worry, It Is coming!
  216. Storage Strategies – Mixed Systems and Review
  217. Storage Strategies – Random Chaotic and ABC
  218. Storage Strategies – Fixed Location
  219. Storage Strategies – Even More Stacking Options
  220. Storage Strategies – Stacking Options
  221. Flexible Manpower Lines 4 – How-To do Flexible Manpower Lines
  222. Flexible Manpower Lines 3 – Example Line
  223. Flexible Manpower Lines 2 – Alternatives and Example
  224. Flexible Manpower Lines 1 – Introduction
  225. What Is Kaizen?
  226. 225th Anniversary of the Death of Josiah Wedgwood – Father of Science in Manufacturing
  227. 115 Years after the Birth of Joseph Juran
  228. When and How to Use Extra Kanban
  229. More Reasons for Working Less
  230. One Up One Down – Approach to Manage Manual Production Lines
  231. The Inner Workings of Amazon Fulfillment Centers – Part 6
  232. The Inner Workings of Amazon Fulfillment Centers – Part 5
  233. The Inner Workings of Amazon Fulfillment Centers – Part 4
  234. The Inner Workings of Amazon Fulfillment Centers – Part 3
  235. The Inner Workings of Amazon Fulfillment Centers – Part 2
  236. The Inner Workings of Amazon Fulfillment Centers – Part 1
  237. Industry 4.0 Tour in Germany – A Van Full of Nerds – Presentations and Tryouts
  238. Industry 4.0 Tour in Germany – A Van Full of Nerds – Kärcher and Siemens
  239. Industry 4.0 Tour in Germany – A Van Full of Nerds – Bosch Reutlingen Wafer Fab
  240. Industry 4.0 Tour in Germany – A Van Full of Nerds – Trumpf Gerlingen
  241. Industry 4.0 Tour in Germany – A Van Full of Nerds – ABB Stotz-Kontakt
  242. Industry 4.0 Tour in Germany – A Van Full of Nerds – Overview and Audi
  243. Happy 6th Birthday, AllAboutLean.com
  244. Cardboard Engineering – Alternatives
  245. Cardboard Engineering – Workshop
  246. Cardboard Engineering – Preparation
  247. Mixed Model Sequencing – Summary
  248. Mixed Model Sequencing – Complex Example Verification
  249. Mixed Model Sequencing – Complex Example Sequencing 2
  250. Mixed Model Sequencing – Complex Example Sequencing 1
  251. Mixed Model Sequencing – Complex Example Data Basis
  252. Mixed Model Sequencing – Complex Example Introduction
  253. Mixed Model Sequencing – Basic Example Sequencing
  254. Mixed Model Sequencing – Basic Example Workload and Buffering
  255. Mixed Model Sequencing – Basic Example Introduction
  256. Mixed Model Sequencing – Adjust Capacity
  257. Mixed Model Sequencing – Just Make the Problem Go Away
  258. Mixed Model Sequencing – Introduction
  259. On Adjusting Supervisor Workload
  260. On the Span of Control
  261. Diseconomies of Scale
  262. Relation between Quantity and Cost in Manufacturing
  263. Maintaining Weak FIFO in Parallel FIFO Lanes
  264. Maintaining Strong FIFO in Parallel FIFO Lanes
  265. The Power of Six: Time and Money for Parts of Your Value Stream
  266. The Power of Six: Relation between Time and Money in Manufacturing
  267. 150 Years after the Birth of Albert Kahn
  268. The Toyoda Model G Loom (with Videos)
  269. Production Control with COBACABANA
  270. Production Sequences: FCFS, EDD, and Others
  271. Delivery Sequences: FIFO, LIFO, and Others
  272. How to Make CONWIP Loops
  273. Should You Use Physical or Digital Kanban Cards?
  274. Hoshin Kanri and the Kanri Noryoku Program: Rejuvenating Toyota
  275. Hoshin Kanri – Part 4: The X-Matrix?
  276. Hoshin Kanri – Part 3: Hierarchical Hoshins
  277. Hoshin Kanri – Part 2: PDCA
  278. Hoshin Kanri – Part 1: The To-Do List
  279. How Cheap Can You Make it?
  280. 25 Years after W. Edwards Deming
  281. Point-of-Use Provider Routing
  282. Point-of-Use Provider Calculations
  283. Introduction to Point-of-Use Providers (or Mizusumashi)
  284. Lean Construction
  285. Example of Problem Solving – Japanese Men’s Relay Team Rio 2016
  286. A Good Standard Needs No Explanation
  287. External Milk Runs
  288. Frequently Asked Questions for Milk Runs
  289. Milk Run Layout
  290. Calculating the Material for Your Milk Run
  291. Milk Run Basics
  292. Introduction to Milk Runs
  293. Just in Time at Hyundai Mobis in Korea
  294. Toyota Kata
  295. Happy 5th Birthday AllAboutLean.com
  296. Calculating the Number of POLCA Cards
  297. Advantages and Disadvantages of POLCA
  298. What Is POLCA?
  299. Lean and Industry 4.0
  300. Examples of Jidoka
  301. The Philosophy and Practicality of Jidoka
  302. What Exactly Is Jidoka?
  303. All About 5 Why
  304. Toyota Standard Work – Part 3: Standard Work Layout
  305. Toyota Standard Work – Part 2: Standard Work Combination Table
  306. Toyota Standard Work – Part 1: Production Capacity
  307. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 2
  308. Disabled Employees in Manufacturing – Omron Taiyo in Japan – Part 1
  309. My Workshop Structure for Creative Problem Solving
  310. Creative Provocation, Reverse Brainstorming, and Analogy
  311. Fishbone Diagrams and Mind Maps
  312. How to Do Brainstorming
  313. Leading with Confidence
  314. Effect of Prioritization on Waiting Times
  315. The Grand Tour of Japanese Automotive – Subaru
  316. The Grand Tour of Japanese Automotive – Suzuki
  317. The Grand Tour of Japanese Automotive – Mazda
  318. The Grand Tour of Japanese Automotive – Mitsubishi
  319. The Grand Tour of Japanese Automotive – Honda Kumamoto
  320. The Grand Tour of Japanese Automotive – Honda Sayama
  321. The Grand Tour of Japanese Automotive – Nissan
  322. The Grand Tour of Japanese Automotive – Overview and Toyota
  323. Continued Evolution of the Toyota Assembly Line
  324. More on TWI Programs
  325. JM: Training within Industry – Job Methods
  326. JR: Training within Industry – Job Relations
  327. JI: Training within Industry – Job Instructions
  328. Training within Industry – TWI – Oldies but Goldies
  329. Heroes, Firefighting, and Corporate Culture
  330. The Dark Side of Japanese Working Society
  331. The Toyota Employee Evaluation System
  332. Anatomy of the Toyota Kanban
  333. Monozukuri – Japanese Work Ethics
  334. A Small Dice Game for the Kingman Formula
  335. Twelve Ways to Create Space around Your Assembly – Part 2
  336. Twelve Ways to Create Space around Your Assembly – Part 1
  337. Structured Approach to Material Supply for Assembly – Part 2
  338. Structured Approach to Material Supply for Assembly – Part 1
  339. The Challenges of Material Supply for Assembly
  340. Karakuri Kaizen Examples
  341. Fundamentals of Karakuri Kaizen
  342. Introduction to Karakuri Kaizen
  343. Industry 4.0 – What Works, What Doesn’t
  344. How to Deal With Long Delivery Times
  345. The Kingman Formula – Variation, Utilization, and Lead Time
  346. Ship to Line
  347. Happy 4th Birthday AllAboutLean.com
  348. Just in Sequence Part 3 – What Can Go Wrong
  349. Just in Sequence Part 2 – How to Do It
  350. Just in Sequence Part 1 – What Is It?
  351. Different Ways to Establish a Pull System – Part 2
  352. Different Ways to Establish a Pull System – Part 1
  353. How to See Visual Management
  354. Employee Motivation and Lean Implementation – Part 4: Respect for People
  355. Employee Motivation and Lean Implementation – Part 3: Lack of Respect
  356. Employee Motivation and Lean Implementation – Part 2: Money
  357. Employee Motivation and Lean Implementation – Part 1: Carrot and Stick
  358. Changeover Sequencing – Part 2
  359. Changeover Sequencing – Part 1
  360. On Running Changeovers
  361. The Phases of a Changeover
  362. What to Do with SMED: Reduce Lot Size or Increase Work Time?
  363. Where Lean Went Wrong – A Historical Perspective
  364. Strategies for Mass Customization
  365. Material Flow in the Arsenal of Venice 1797
  366. The Arsenal of Venice
  367. Pacing of Flow Lines 2 – Continuously Moving Line
  368. Pacing of Flow Lines 1 – Unstructured and Pulse Line
  369. Lean Is Tough – The Phases of a Lean Transformation
  370. Organize Your Production Sequence – 3: Flow Shop
  371. Organize Your Production Sequence – 2: Job Shop
  372. Organize Your Production Sequence – 1: Project Shop
  373. The Lean Mindset – Te & Kaffi in Iceland
  374. Lean Tales in Japan: The Japanese Supermarket Checkout
  375. The Lean Rabbit Chase in a U-Line
  376. 150th Anniversary of the Birth of Sakichi Toyoda
  377. The Chaku Chaku Line
  378. How to Determine Your Lot Size – Part 3
  379. How to Determine Your Lot Size – Part 2
  380. How to Determine Your Lot Size – Part 1
  381. The Lean Bucket Brigade – Part 2: Details and Caveats
  382. The Lean Bucket Brigade – Part 1: Overview
  383. Dealing with Uncertainty
  384. How to Ramp Up a Kanban System – Part 2: The Switch
  385. How to Ramp Up a Kanban System – Part 1: Preparation
  386. Kanban Card Design
  387. Interview on the David Pakman Show on the Future of Manufacturing
  388. Line Layout Strategies – Part 3: Merging
  389. Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines
  390. Line Layout Strategies – Part 1: The Big Picture
  391. Loss of Material: Theft!
  392. Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!
  393. Toyota’s and Denso’s Relentless Quest for Lot Size One
  394. “Lean Standard” ISO 18404 – A Questionable Idea …
  395. Volkswagen Supplier Relations Failure
  396. Can you tell your Bottleneck from your Inventory?
  397. The Many Different Flavors of the OEE
  398. Happy 3rd Birthday AllAboutLean.com
  399. The History of Manufacturing – Part 4: Toyota and Lean
  400. The History of Manufacturing – Part 3: Luddism to Henry Ford
  401. The History of Manufacturing – Part 2: Middle Ages to Industrial Revolution
  402. The History of Manufacturing – Part 1: Prehistory to Antiquity
  403. Good and Bad Ways to Calculate the OEE
  404. How to Prioritize Your Work Orders – Prioritization of Made to Order
  405. How to Prioritize Your Work Orders – Prioritization of Made to Stock
  406. How to Prioritize Your Work Orders – The VIP Lane
  407. How to Prioritize Your Work Orders – Basics
  408. How to Make “Just in Time” Work – Part 2
  409. How to Make “Just in Time” Work – Part 1
  410. What Is “Just in Time”?
  411. Tales from Japan – Lean in the Japanese Public Toilet
  412. How Product Variants Influence Your Inventory
  413. The Relation between Inventory, Customer Takt, and Replenishment Time
  414. Using Lots of Effort and Money to Demotivate Your People
  415. The Curious Case of 100% Work Performance
  416. How Operators Hide the True Workload
  417. The Many Flavors of the PDCA
  418. Common Mistakes with the PDCA (and Some History)
  419. The Key to Lean – Plan, Do, Check, Act!
  420. Supermarket vs. FiFo – What Requires Less Inventory?
  421. The A3 Report – Part 3: Limitations and Common Mistakes
  422. The A3 Report – Part 2: Content
  423. The A3 Report – Part 1: Basics
  424. On the Benefits of a Pencil in Lean
  425. Visit the Shop Floor or Your People Will Fool You! – Genchi Genbutsu
  426. Line Balancing Part 6 – Tips and Tricks for Balancing
  427. Line Balancing Part 5 – Balancing Using Paper
  428. Line Balancing Part 4 – OEE Usage and Flexibility
  429. Line Balancing Part 3 – OEE Caveats
  430. Line Balancing Part 2 – Duration of Tasks
  431. Line Balancing Part 1 – Data Overview
  432. The Challenges of Lean Administration
  433. The Problems of Cost Accounting with Lean
  434. Taiichi Ohno’s Chalk Circle
  435. A Critical Look at Industry 4.0
  436. Lean for Refugees
  437. How to Reduce Your Inventory
  438. Why Do We Have Inventory?
  439. American Automotive Market Strategy of Toyota and Others
  440. What Is Your Production Capacity?
  441. How to Use an Andon – and How Not To
  442. All About Andon
  443. The Three Fundamental Ways to Decouple Fluctuations
  444. Pay Attention to Details – Operator Training at Toyota and Scania
  445. Cycle Times for Manual Processes
  446. How to Measure Cycle Times – Part 2
  447. How to Measure Cycle Times – Part 1
  448. Pitfalls of Takt Times
  449. How to determine Takt Times
  450. On the Different Ways to Measure Production Speed
  451. All About Swim Lane Diagrams
  452. Happy 2nd Birthday AllAboutLean.com
  453. All About Spaghetti Diagrams
  454. Practical Tips for Value Stream Mapping
  455. Basics of Value Stream Maps
  456. Overview of Value Stream Mapping Symbols
  457. When to Do Value Stream Maps (and When Not!)
  458. Bubble Diagrams to Visualize Material Flow
  459. Visualize Your System – Overview of Diagrams in Manufacturing
  460. 230 Years of Interchangeable Parts – A Brief History
  461. A Eulogy for Little’s Law
  462. Theory and Practice of Supermarkets – Part 2
  463. Theory and Practice of Supermarkets – Part 1
  464. Why Pull Is So Great!
  465. The (True) Difference Between Push and Pull
  466. Twenty-five Years after Ohno – A Look Back
  467. How to Find a Good Lean Consultant
  468. Definition of Lean Production
  469. How to Make 5S Stick
  470. How 5S Works
  471. Muda, Mura, Muri: The Three Evils of Manufacturing
  472. More On Cuba’s Planned Economy: Cuban Industry
  473. Lies, Damned Lies, and KPI – Part 3: Countermeasures
  474. Lies, Damned Lies, and KPI – Part 2: Effects of Fudging
  475. 100th Anniversary of the Death of Frederick Winslow Taylor, the Father of Modern Scientific Management
  476. Lies, Damned Lies, and KPI – Part 1: Examples of Fudging
  477. The Seven Types of Waste (Muda) – Now with 24 More Types of Waste Absolutely Free!
  478. How a Planned Economy Can Screw Up an Entire Country – Analogy between Cuba’s Communist Economy and Push Systems
  479. Benefits and Flaws of CONWIP in Comparison to Kanban
  480. Frequently Asked Questions on CONWIP Systems – Part 2
  481. Frequently Asked Questions on CONWIP Systems – Part 1
  482. Basics of CONWIP Systems (Constant Work in Progress)
  483. Shop Floor Etiquette – Part 2
  484. Shop Floor Etiquette – Part 1
  485. Introduction to One-Piece Flow Leveling – Part 2 Implementation
  486. Introduction to One-Piece Flow Leveling – Part 1 Theory
  487. The Folly of EPEI Leveling in Practice – Part 2
  488. The Folly of EPEI Leveling in Practice – Part 1
  489. Theory of Every Part Every Interval (EPEI) Leveling & Heijunka
  490. An Introduction to Capacity Leveling
  491. Why Leveling (Heijunka) is important
  492. A Critical Look at Goldratt’s Drum-Buffer-Rope Method
  493. Bottleneck Management Part 3 – Bottleneck Decoupling and Capacity Improvement
  494. Bottleneck Management Part 2 – Improve Bottleneck Planning
  495. Bottleneck Management Part 1 – Introduction and Utilization
  496. Common Mistakes of Top Executives – A look at “Undercover Boss”
  497. Top Five Cases When NOT to Use a FiFo
  498. Eight Rules for Total Gridlock in the Organization (Video)
  499. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 2)
  500. A Successful Example of Lean Implementation – Trumpf and its Synchro Manufacturing System (Part 1)
  501. The Advantage of Handwritten Data on the Shop Floor
  502. The FiFo Calculator – Determining the Size of your Buffers
  503. Visual Management during World War II – A Visit to the Lascaris War Rooms in Malta
  504. Happy 1st Birthday AllAboutLean.com
  505. Determining the Size of Your FiFo Lane – The FiFo Formula
  506. Theory and Practice on FiFo Lanes – How Does FiFo Work in Lean Manufacturing?
  507. Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness
  508. Facing Change in Modern Manufacturing Systems – The Difference between Flexible, Agile, Reconfigurable, Robust, and Adaptable Manufacturing Systems
  509. The Hidden and not-so-hidden costs of Inventory
  510. Manufacturing – A key stepping stone on the Road to Prosperity
  511. The Bottleneck Walk – Practical Bottleneck Detection Part 2
  512. The Bottleneck Walk – Practical Bottleneck Detection Part 1
  513. Mathematically Accurate Bottleneck Detection 1 – The Average Active Period Method
  514. Mathematically Accurate Bottleneck Detection 2 – The Active Period Method
  515. Common Bottleneck Detection Methods that do NOT work!
  516. About Shifting Bottlenecks
  517. Culture of Quality – A Comparison of Toyota and GM Recalls
  518. Toyota Employee Relationship Crisis and Countermeasures 1990’s
  519. How Many Kanbans? – Estimation Approach and Maintenance
  520. How Many Kanbans? – The Kanban Formula, Part 2
  521. How Many Kanbans? – The Kanban Formula, Part 1
  522. Cost of Complexity
  523. The Problem of Losing Kanban – Different Kanban Types
  524. The Difference Between Lean and Six Sigma
  525. A Lean Obituary for Maybach – A Cautionary Tale About Cost of Complexity
  526. How to Manage Your Lean Projects – Prioritize
  527. How to Manage Your Lean Projects – Number of Active Projects
  528. How a Little Bit of Industrial Espionage Started the Industrial Revolution
  529. SMED – Creative Quick Changeover Exercises and Training
  530. The History of Quick Changeover (SMED)
  531. Quick Changeover Basics – SMED
  532. Poka Yoke Training – Simple Mistake Proofing Game
  533. Dress for Success in Lean Manufacturing
  534. On the Lean Guru Shigeo Shingo
  535. Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant
  536. Lean is Zero Defects? – I don’t think so!
  537. Consistency at Toyota – The Board of Directors of the Toyota Motor Company
  538. Japanese Standard Pointing and Calling (Video)
  539. Value Stream Mapping – Why to Start at the Customer Side
  540. Simple Triangle Kanban System for Office Supplies
  541. Ten Rules When to Use a FIFO, When a Supermarket – The Rules
  542. Ten Rules When to Use a FIFO, When a Supermarket – Introduction
  543. Hell is Other People – Workplace Conflict between Managers and the Managed
  544. Internal Threat to the Toyota Production System Due to New Hiring Practices
  545. Extended Lean Tool Kit for Shop Floor Improvement Projects
  546. The Tale of Taylor and Gilbreth
  547. Know Your Priorities!
  548. Seven Gadgets for the Basic Lean Toolkit
  549. Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory
  550. Japanese Multidimensional Problem Solving
  551. Lean Where You Least Expect It – Toilet Paper Origami
  552. How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!
  553. Make Your Plant Tour a Success!
  554. Visit to Euromold for the Latest in 3D Printing
  555. Ancient Roman Management Techniques
  556. What the OEE is Good for … and What it’s Not
  557. Top Three Methods on how to Fudge Your OEE
  558. How to Measure OEE
  559. What is OEE? – Definition of OEE
  560. New Professor, New Blog

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