Fake Flow?
"Many companies change the physical layout of equipment and think that one-piece flow will automatically follow. But they often are creating fake flow. An example of fake flow would be…
Too Much Inventory Reduction Can Hurt
"Sustaining continuous flow also serves to surface any problem that would inhibit that flow. In essence, the creation of flow forces the correction of problems, resulting in reduced waste. We…
Discover the Weak Points and Improve
"So physically shifting from batch and queue operations…to one-piece flow without inventory almost guarantees you will encounter many more problems. So why do it? Precisely to allow the processes to…
Flow and the Pursuit of Perfection
"Connected processes force all team members to strive for perfection. [Toyota Manager] Ohno taught that lowering the 'water level' of inventory exposes problems (like rocks in the water), and you…
The Lean Definition of Flow
Continuous Flow Producing and moving one item at a time (or a small and consistent batch of items) through a series of processing steps as continuously as possible, with each…
The Benefit of One-Piece Flow
"One of the greatest benefits of one-piece flow is that problems surface and challenge people to think and improve." The Toyota Way 2nd Edition by Jeffrey K. Liker (McGraw Hill,…
Lean, Christian Belief, and “Common Grace”
Bible-believing Christians know that Adam and Eve's fall into sin brought death and destruction to the human race. The "fall" damaged both people and creation. In Genesis 3:16-19, we read…
Does 5S = Lean??
"Unfortunately, some companies seem to think 5S [the system of organizing and labeling work areas] is lean production. ...The Toyota Production System is not about using 5S to neatly organize and…
Confirm that 5S is Being Followed: Audits
"Do 5S audits periodically, give scores to different groups, and hold them accountable for improving their scores. Toyota team leaders and group leaders audit their processes regularly, often with daily…
5S: Treating Workers like “Surgeons”
"It is useful to think of the operator [worker] as a surgeon. Obviously, a surgeon needs to focus completely on the patient. The last thing you want is the surgeon…
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