Old Lean Dude
A Blog About Understanding The Toyota Production System and Gaining Its Full Benefits, brought to you by "The Toast Guy"
Category Archives: set-up reduction
Can't See
Leave a reply
My friend and mentor, Gifford Brown, told me a remarkable story some time back about a visit to his plant in 1987 by Shigeo Shingo in which Shingo,..
This entry was posted in
old lean dude,
lean manufacturing,
Toast Kaizen,
internal customer,
kaizen,
Shingo Conference,
bruce hamilton,
toyota production system,
shigeo shingo,
set-up reduction,
quick changeover
on
February 13 , 2014.
What is Advanced Manufacturing?
I am looking for some help to answer this question. Seeking illumination, I recently attended a presentation offered through CCAT, a non-profit..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
SMED,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
change over,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
June 04 , 2012.
Incremental Elimination of Weeds
Spring is my favorite season because of the spirit of renewal it brings with it. So here is a post dedicated to spring that is inspired by a comment..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
April 24 , 2012.
What does 3P Stand For?
3P, “Production Preparation Process,” is a method introduced to the US in the mid-80’s by Chihiro Nakao, a contemporary of Mr. Ohno, and founder of..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
April 19 , 2012.
JIT, Boy Scouts, and Stooges
I take my work very seriously, but sometimes when I have excess idle time (like on the red-eye from Phoenix to Boston), I’ll have a whimsical idea...
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
April 06 , 2012.
Shingo's Network
With the International Shingo Prize Conference just a month away, I thought a short post about Shigeo Shingo and the Prize named in his honor would..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
March 30 , 2012.
John's Box
Some years back while working in an administrative department I encountered a curious condition. With about a half-dozen employees, I was following..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
March 14 , 2012.
Airplane
I think there are no new airplane stories left for those of us who take to the not-always-friendly skies, but having been on one of those super delay..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura,
searching
on
March 05 , 2012.
They Assessment
Over years of listening to persons describe their work, one single word has surfaced repeatedly as a barometer of what is frequently called..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
lean development,
TPM,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
lean tools,
Muri,
ryuji fukuda,
shigeo shingo,
lean assessment,
standardized work,
set-up reduction,
value stream mapping,
mura
on
February 27 , 2012.
WYSIWYG
Computer geeks over the age over 40 will recall that once upon a time, the images of text and graphics that appeared on computer screens bore little..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
visual control systems,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
February 15 , 2012.
Signs
Do you remember a post-hippie era song called Signs? The song’s refrain came to mind recently during a workplace walkthrough:
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
visual control systems,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
February 03 , 2012.
Cost Subtraction
Last week, a drive-by a 99 Cent Store (see photo) reminded me of my first real job in an industrial marketing department. In the 1970’s, one function..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
January 23 , 2012.
5S First?
Some time ago, while speaking at a conference in the land down under, I was taken to task by a participant for suggesting, “5S is usually the first..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
January 12 , 2012.
Standards Part 1
I attended a gathering of healthcare providers recently to participate in a site review and listen to some nice TPS success stories. During a Q&A..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
December 06 , 2011.
Acts of God
Several weeks ago in New England, the rants of angry electric utility patrons filled the evening news. Accusations of greed and incompetence were..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
December 01 , 2011.
Lean Thanks
The upcoming holiday is my second favorite (after New Years), first because it’s energizing to reflect on things to be happy about, and second..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
November 22 , 2011.
The Ear of the Beholder
A short time after I moved into operations as the VP of manufacturing, our assembly department made an early and, dare I say, imperfect attempt to..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
November 18 , 2011.
First Job Lessons
Early job experiences can have a profound impact on how we approach the workday. Here is one of mine from my very first job:
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
November 08 , 2011.
Illogical Progression
This post is a follow-up to one from September on policy deployment, sometimes called a ‘roadmap’ for improvement.’ It’s more than that in that it..
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
November 02 , 2011.
Passing the Baton
There is an abundance of symbolism in the phrase “passing the baton”.
This entry was posted in
old lean dude,
TPS,
lean manufacturing,
six sigma,
lean thinking,
GBMP,
Toast Kaizen,
muda,
autonomation,
process improvement,
kaizen,
lean government,
hoshin kanri,
TPM,
5S,
true north,
lean summit,
poka-yoke,
automation,
lean in healthcare,
optimization,
toyota production system,
inventory,
Northeast Shingo Prize,
made in america,
Muri,
shigeo shingo,
standardized work,
Hajime Ohba,
set-up reduction,
value stream mapping,
mura
on
October 28 , 2011.