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…
“5S” makes Work Areas Safe, Productive, and Reliable
"The objective of workplace organization is to create a functionally organized work environment and not to simply give the appearance that things are organized." Lean Office and Service Simplified by…
2 Pillars of Lean: Discipline and Accountability
"This culture (at Toyota) has, in our view, two pillars—the discipline to follow a path of continuous problem solving and self-improvement, and accountability to work standards, fellow team members, company…
More Standards = More Creativity??
"The paradox of Lean is that the more structure and standards you have in place, the more flexible and creative you can become." Flatlined: Why Lean Transformations Fail and What…
Who Has Permission to Change Standards?
"At Toyota (like most other manufacturers), there are certain standards (safety, equipment settings, quality tests, etc.) which are determined and set by various professionals. The question comes up, how can…