All Posts and Pages

Archive of All Posts:

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

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