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The Lean Bucket Brigade – Part 2: Details and Caveats

The Lean Bucket Brigade – Part 2: Details and Caveats | AllAboutLean.com | Scoop.it
In my last post I explained the basics of the bucket brigade as a self-organizing manufacturing line. The key to making this system work is the process for handing over the part to the next worker. An unsuitable hand-over could mean lots of waiting time for the workers. Hence, I would like to go... http://www.allaboutlean.com/bucket-brigade-2/
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The Lean Rabbit Chase in a U-Line

The Lean Rabbit Chase in a U-Line | AllAboutLean.com | Scoop.it
There are different ways to manage workers in an manual U-line. One of these methods is known as the “Rabbit Chase,” also known as the “Caravan Approach” or “Operators-in-Motion.” The workers always move in a circle and handle all processes in sequence. Introduction Cell with one... http://www.allaboutlean.com/rabbit-chase/
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The Chaku Chaku Line

The Chaku Chaku Line | AllAboutLean.com | Scoop.it
Chaku Chaku is a way to operate a semi-automated manufacturing line. One (or more) workers walk around the line, add parts to the processes, and then start the process. While the process works on the part automatically, the worker adds the next part to the next process, and so... http://www.allaboutlean.com/chaku-chaku-line/
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How to Determine Your Lot Size – Part 2

How to Determine Your Lot Size – Part 2 | AllAboutLean.com | Scoop.it
A good lot size has a significant impact on the performance of the system. In this second post, I look at the influence of the machine batch size on the lot size. I also briefly go into the lot sizes for the processing industry, and also  administrative processes. In my next and last post I will... http://www.allaboutlean.com/lot-size-part-2/
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The Lean Bucket Brigade – Part 2: Details and Caveats

The Lean Bucket Brigade – Part 2: Details and Caveats | AllAboutLean.com | Scoop.it
In my last post I explained the basics of the bucket brigade as a self-organizing manufacturing line. The key to making this system work is the process for handing over the part to the next worker. An unsuitable hand-over could mean lots of waiting time for the workers. Hence, I would like to go... http://www.allaboutlean.com/bucket-brigade-2/
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Dealing with Uncertainty

Dealing with Uncertainty | AllAboutLean.com | Scoop.it
A lot of decisions in lean manufacturing have uncertainty. How many products will I sell (and what is my customer takt)? Which layout is more efficient? Should I believe expert A or expert B? Uncertainty is a part of life in manufacturing. In fact, the higher up you go in the hierarchy, the more... http://www.allaboutlean.com/dealing-with-uncertainty/
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How to Ramp Up a Kanban System - Part 1: Preparation

How to Ramp Up a Kanban System - Part 1: Preparation | AllAboutLean.com | Scoop.it
Designing a kanban system on paper is much easier than implementing it on the shop floor. In many of my previous posts I discussed the design of a kanban system in detail. In these two posts I will discuss the steps needed to actually put the system on the ground.  This first post is the ... http://www.allaboutlean.com/kanban-ramp-up-1/
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Interview on the David Pakman Show on the Future of Manufacturing

Interview on the David Pakman Show on the Future of Manufacturing | AllAboutLean.com | Scoop.it
Recently I had the exciting opportunity to be interviewed on the David Pakman Show on American TV, where I talked about the future of manufacturing, especially in America. Our subjects of discussion ranged from “bringing jobs back,” to the presidential election, to the carbon tax and... http://www.allaboutlean.com/interview-on-the-david-pakman-show-on-the-future-of-manufacturing/
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Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines

Line Layout Strategies – Part 2: I-, U-, S-, and L-Lines | AllAboutLean.com | Scoop.it
The layout of a line can make quite a difference in the performance of your line. The U-line is most famous, although in my view while good it may not be the right thing for all situations. There is also the I-line, the S-line, and the U-line. In my last post I described some general thoughts on... http://www.allaboutlean.com/line-layout-i-s-u-l-lines/
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Loss of Material: Theft!

Loss of Material: Theft! | AllAboutLean.com | Scoop.it
Most of the material you purchase eventually goes (hopefully) to the customer. Some will be waste, others may be scrap. Yet a small part is also likely to be stolen, probably by your own employees. In this post I will look at the effects of theft and give you some industry examples. Where Does... http://www.allaboutlean.com/loss-of-material-theft/
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Toyota's and Denso's Relentless Quest for Lot Size One

Toyota's and Denso's Relentless Quest for Lot Size One | AllAboutLean.com | Scoop.it
Just when you need it … A famous step toward perfection in a lean production system is a lot size of one. However, few people realize what enormous effort and rigor Toyota applies to achieve this goal. During my visit to a Toyota plant and the APMS conference in Tokyo  in 2015, I saw quite ... http://www.allaboutlean.com/toyota-lot-size-one/
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Volkswagen Supplier Relations Failure

Volkswagen Supplier Relations Failure | AllAboutLean.com | Scoop.it
In the last months, there has been an unprecedented power struggle between Volkswagen and its suppliers. Two of the suppliers stopped delivering, leading to a full stop of multiple production lines at six Volkswagen plants, including its main plant Wolfsburg. This whole mess comes on top of the ... http://www.allaboutlean.com/volkswagen-prevent/
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The Many Different Flavors of the OEE

The Many Different Flavors of the OEE | AllAboutLean.com | Scoop.it
If imitation is the sincerest form of flattery, the OEE (Overall Equipment Effectiveness or Efficiency) is indeed one of the most appreciated measures in lean. I counted at least eight different variants and adaptions of the basic OEE – although let me tell you that I am not impressed with all o... http://www.allaboutlean.com/oee-flavors/
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The History of Manufacturing – Part 4: Toyota and Lean

The History of Manufacturing – Part 4: Toyota and Lean | AllAboutLean.com | Scoop.it
Most of our prosperity and wealth is based on our ability to manufacture faster, better, and cheaper than ever before.To announce the publication of my first book “Faster, Better, Cheaper” in the History of Manufacturing: From the Stone Age to Lean Manufacturing and Beyond here is the fourth and ... http://www.allaboutlean.com/firstlecture_hom_4/
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150th Anniversary of the Birth of Sakichi Toyoda

150th Anniversary of the Birth of Sakichi Toyoda | AllAboutLean.com | Scoop.it
The King of Inventors Exactly 150 years ago, on February 14, 1867, Sakichi Toyoda (豊田 佐吉 Toyoda Sakichi)  was born. He is known in Japan as the King of Inventors (which is probably a bit of an exaggeration), father of the Japanese Industrial Revolution, and also the founder of the Toyota... http://www.allaboutlean.com/150th-anniversary-sakichi-toyoda/
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How to Determine Your Lot Size – Part 3

How to Determine Your Lot Size – Part 3 | AllAboutLean.com | Scoop.it
This is the third and final post on lot sizes (Part 1 and Part 2). After considering all the factors of the processes and inventories (changeover time, batch size, customer order size, and container and shipment size), we now look at how to set up the information flow. This is especially... http://www.allaboutlean.com/lot-size-part-3/
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How to Determine Your Lot Size – Part 1

How to Determine Your Lot Size – Part 1 | AllAboutLean.com | Scoop.it
There are a few factors that can influence lot size: machine batch size, changeover time, size of the container, shipment sizes, and the size of your customers’ orders, which then are combined in the set up of the information flow. All of these factors can be influenced to move toward the... http://www.allaboutlean.com/lot-size-part-1/
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The Lean Bucket Brigade – Part 1: Overview

The Lean Bucket Brigade – Part 1: Overview | AllAboutLean.com | Scoop.it
Many topics in lean address how to deal with uncertainty and fluctuations (or mura for unevenness). There is a particularly neat trick for manual lines that self-organizes fluctuations in the workload: the Bucket Brigade! It does have some advantages, but it also has quite a few limitations and... http://www.allaboutlean.com/bucket-brigade-1/
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How to Ramp Up a Kanban System - Part 2: The Switch

How to Ramp Up a Kanban System - Part 2: The Switch | AllAboutLean.com | Scoop.it
In my last post I described how to prepare for the implementation of a kanban system. This post goes into more detail on the actual change to the new kanban system. You surely know that every part should have a kanban. But what do you do if you have more kanban than parts? What do you do if you... http://www.allaboutlean.com/kanban-ramp-up-2/
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Kanban Card Design

Kanban Card Design | AllAboutLean.com | Scoop.it
A kanban is, in its basics, information to reproduce or reorder parts. Hence, in its most basic form it has to say “make me this part” or “bring me this part.” While such very simple kanban systems are possible, usually it helps to include other information on the kanban... http://www.allaboutlean.com/kanban-card-design/
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Line Layout Strategies – Part 3: Merging

Line Layout Strategies – Part 3: Merging | AllAboutLean.com | Scoop.it
In my last two posts (here 1 and here 2) I discussed line layouts, including the famous U-line. In the last post of this small series, I would like to wrap up the line layout discussions, looking at merging material flows and other things. Merging Material Flows Assembly lines are the prime... http://www.allaboutlean.com/line-layout-strategies-part-3-merging/
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Line Layout Strategies – Part 1: The Big Picture

Line Layout Strategies – Part 1: The Big Picture | AllAboutLean.com | Scoop.it
In flow shops, you have a production line of some sort. This may be an assembly line or a manufacturing line; this may be automatic or manual. In lean, you often hear about the famous U-line. While this is a great solution, it may not fit all problems. Depending on the surrounding conditions, a... http://www.allaboutlean.com/line-layout-strategies-part-1-the-big-picture/
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Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA!

Reddit: I am Chris Roser, a professor studying the past, present, and future of manufacturing, and just published my first book. AMA! | AllAboutLean.com | Scoop.it
On September 27, I did my first Reddit: “I am a … ask me anything.” With almost four hundred comments, I consider it a quite successful AMA. I am Chris Roser, a professor for production management; a lean expert; a Toyota, Bosch, and McKinsey alumnus; and I’m interested... http://www.allaboutlean.com/reddit-ama/
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"Lean Standard" ISO 18404 – A Questionable Idea ...

"Lean Standard" ISO 18404 – A Questionable Idea ... | AllAboutLean.com | Scoop.it
Recently I learned about a new ISO 18404 standard certifying lean and Six Sigma organizations. I think this is a highly questionable idea, with little benefit for the quality of lean manufacturing. This certification madness won’t make much  difference for the quality of lean but will ... http://www.allaboutlean.com/iso-18404/
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Can you tell your Bottleneck from your Inventory?

Can you tell your Bottleneck from your Inventory? | AllAboutLean.com | Scoop.it
On the shop floor it is common wisdom to find the bottleneck based on the inventory. If the buffer is full, the bottleneck is downstream. If the buffer is empty, the bottleneck is upstream. Is this true? My student Carolin Romeser and I spent quite some time verifying this, and found some... http://www.allaboutlean.com/bottleneck-direction-inventory/
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AllAboutLean.com Is Now 3 Years Old!

AllAboutLean.com Is Now 3 Years Old! | AllAboutLean.com | Scoop.it
Yayyy! AllAboutLean.com is now 3 years old! Three years ago on September 1, 2013, I became a professor and wrote the first post on my blog. Now, 163 blog posts and one book later, I am still enjoying it immensely! I feel that after three years of weekly (longer) postings, I am now no longer a... http://www.allaboutlean.com/3rd-birthday/
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