Process Confirmation | AllAboutLean.com

Lean Is Tough – The Phases of a Lean Transformation

Christoph Roser — Tue, 04 Apr 2017 11:00:57 +0000

Sometimes, consultants sell lean as a quick and easy way to success that pays for itself. Unfortunately, this is usually not true, as many companies have found out the hard way. Getting lean in a company is similar to getting a lean body; it is usually neither quick nor easy. Let me show you the ... Read more

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Common Mistakes with the PDCA (and Some History)

Christoph Roser — Tue, 26 Apr 2016 11:00:53 +0000

In my previous post I explained how the PDCA (Plan, Do, Check, Act) should work. However, while most people know the PDCA in theory, I find that the practical implementation is often lacking. And, quite frankly, I am also sometimes sloppy with the PDCA way more often than I would like to admit. Time for ... Read more

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The Key to Lean – Plan, Do, Check, Act!

Christoph Roser — Tue, 19 Apr 2016 11:00:33 +0000

Plan-Do-Check-Act (or PDCA) is one of the key elements in lean manufacturing, or for that matter in any kind of improvement process. In my view, it is the most basic framework for any kind of change. All other lean tools are only on top of the PDCA. In my experience, most lean projects in the ... Read more

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Common Mistakes of Top Executives – A look at “Undercover Boss”

Christoph Roser — Sun, 26 Oct 2014 11:00:13 +0000

I occasionally watch the reality show Undercover Boss, where top executives work undercover in their own companies. Over and over again I see these managers making the same mistake: They have no understanding whatsoever of what is really happening on the front lines. It is a typical case of not going to the shop floor ... Read more

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Corporate Culture on Quality Starts at the Top – A Small Anecdote on Organizational Blindness

Christoph Roser — Sun, 10 Aug 2014 11:00:17 +0000

Quality starts at the top with management. Top executives like to talk about quality, but employees below usually know very well if the manager only talks the talk or also walks the walk. Words are cheap. Quality (and pretty much everything else that is important) requires attention by management. Of course, the CEO cannot check ... Read more

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The Problem of Losing Kanban – Different Kanban Types

Christoph Roser — Sun, 20 Apr 2014 11:00:39 +0000

Pull production using Kanban is one of the major achievements of the Toyota Production System and hence lean manufacturing. The work in progress is limited by the number of Kanban. Overproduction is avoided by producing only if a part is taken out of the supermarket and the Kanban card is returned to the start of ... Read more

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Japanese Standard Pointing and Calling (Video)

Christoph Roser — Sun, 05 Jan 2014 11:00:20 +0000

During my last trip to Japan, I finally took videos capturing the Japanese Pointing-and-Calling standard. Pointing and calling is a safety standard that started with Japanese train operators but now is widely used in industry. The idea is that whenever you confirm something, you not only look at it, but also point at it and call ... Read more

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Lean Shop Floor Checklist – Top 4 KPI to Watch in the Factory

Christoph Roser — Sun, 20 Oct 2013 11:00:07 +0000

Due to popular demand related to my two posts on “Make Your Plant Tour a Success!” and “How to Misguide Your Visitor – or What Not to Pay Attention to During a Plant Visit!,” I have created a checklist for a lean visit to a manufacturing shop floor for you to download. Take this checklist ... Read more

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