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: shigeo shingo
The First Shingo Prize
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Last month marked the 35th anniversary of the Shingo Prize, an award bestowed each year to recognize organizations that demonstrate the principles..
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Management Kaizen,
Toyota Production System. Lean manufacturing,
shigeo shingo
on
June 15 , 2023.
Tools or Culture?
With our annual Northeast LEAN Conference just a few days away, I want to relate a personal story about the theme of this year’s conference,
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old lean dude,
TPS,
lean manufacturing,
kanban,
continuous improvement,
kaizen,
7 wastes,
Changeover,
SMED,
toyota production system,
shigeo shingo,
enterprise excellence
on
September 14 , 2017.
Reflecting on Waste
For me, Taiichi Ohno and Shigeo Shingo are a bit like the Lennon and McCartney of waste elimination. Together they frame the technical and social..
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old lean dude,
lean manufacturing,
TIMWOODS,
waste,
Taichi Ohno,
shigeo shingo,
7 wastes. Toyota Production System
on
May 15 , 2017.
Cartwheels
Most often when we think of a wheel, it’s in the context of transportation, one of the more obvious and ever-present of the 7 wastes. In fact, the..
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old lean dude,
lean manufacturing,
continuous improvement,
7 wastes,
toyota production system,
shigeo shingo,
eoq
on
January 31 , 2017.
Doormats
One of Shigeo Shingo’s popular status quo targets was engineers, whom he placed in three categories:
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old lean dude,
lean manufacturing,
six sigma,
continuous improvement,
lean engineer,
toyota production system,
design for assembly,
shigeo shingo
on
September 23 , 2016.
Lean By Doing
Early along, as a student of the Toyota Production System (TPS), now referred to as “Lean,” I struggled with some of the concepts and systems. For..
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old lean dude,
lean manufacturing,
kaizen,
5S,
toyota production system,
shigeo shingo
on
September 07 , 2016.
Peripheral Discoveries
The following post is inspired by The Teachings of Don Juan, an anthropological novel from the 1960’s written by Carlos Castaneda chronicling his..
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old lean dude,
lean manufacturing,
GBMP,
kaizen,
toyota production system,
shigeo shingo,
value stream mapping
on
August 16 , 2016.
Profitless Part Proliferation
I wrote a post a little more than five years ago about Variety Reduction Program (VRP), an amazing but little known product design optimization tool...
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old lean dude,
TPS,
lean manufacturing,
GBMP,
Toast Kaizen,
kaizen,
hoshin kanri,
true north,
poka-yoke,
toyota production system,
inventory,
shigeo shingo,
value stream mapping
on
June 27 , 2016.
Eye of the Beholder
Many moons ago when I was just getting started on my lean journey, I visited a large automotive supplier to benchmark pull systems. My own factory..
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old lean dude,
TPS,
lean manufacturing,
kanban,
GBMP,
Toast Kaizen,
kaizen,
TPM,
5S,
true north,
poka-yoke,
toyota production system,
shigeo shingo,
value stream mapping
on
May 20 , 2016.
Indefinite Postponement
Today’s post is inspired by the politically charged gobbledygook we call presidential primaries. This battle of principles turned battle of wills..
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old lean dude,
lean manufacturing,
GBMP,
Toast Kaizen,
kaizen,
hoshin kanri,
true north,
toyota production system,
shigeo shingo,
value stream mapping
on
April 20 , 2016.
Mistake-Proofing Mistakes
There is a popular lore provided by Shigeo Shingo, that the original name for mistake-proofing (Poka-Yoke) was “fool-proofing” (Baka-Yoke). Shingo..
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lean,
old lean dude,
six sigma,
continuous improvement,
standard work,
error-proofing,
pokayoke,
poka-yoke,
toyota production system,
shigeo shingo,
mistake proofing,
manufacturing
on
December 08 , 2015.
Lazy Lean Guy
In 1987, shortly after I became a manufacturing manager, the shop foreman at the time warned me about a young assembler: “Watch out for Michael, he’s..
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old lean dude,
TPS,
lean manufacturing,
continuous improvement,
Taiichi Ohno,
Non-stock production,
toyota production system,
better faster cheaper easier,
shigeo shingo
on
November 12 , 2015.
Burning Platform
A favorite Twilight Zone episode that played Labor Day weekend put me in mind of the stressful push production environment that many organizations..
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old lean dude,
lean manufacturing,
kanban,
7 wastes,
overproduction,
pull production,
push production,
shigeo shingo
on
September 22 , 2015.
P-D Ratios
The last few weeks have been all things Shingo for me including a presentation at the Shingo Institute’s International Conference three weeks ago in..
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old lean dude,
TPS,
lean manufacturing,
GBMP,
muda,
northeast lean conference,
TPM,
bruce hamilton,
lean maturity,
lean in healthcare,
MRP,
shigeo shingo,
culture of improvement
on
May 27 , 2015.
Unreasonability
Sometimes we receive unreasonable and confusing directions, and sometimes we give them. Check out this example.
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old lean dude,
lean manufacturing,
Toast Kaizen,
Shingo Institute,
continuous improvement resolutions,
bruce hamilton,
toyota production system,
shigeo shingo
on
April 13 , 2015.
Artificial Ignorance
For a few years back in the early ‘80’s I fell prey to information automation fascination. I managed an IT department transitioning first from a..
This entry was posted in
old lean dude,
artificial ignorance,
kanban. Bruce Hamiton,
inventory control system,
Eli Goldratt,
Joe Weizenbaum,
MRP,
information automation,
ERP,
basic accounting system,
shigeo shingo
on
January 29 , 2015.
Dead See Scrolls
I participated recently in the AME conference in Jacksonville, Florida; a terrific rally for manufacturing excellence with the tongue-twisting theme..
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old lean dude,
lean manufacturing,
GBMP,
Taiichi Ohno,
TEI,
respect for people,
bruce hamilton,
People powered excellence,
employee engagement,
shigeo shingo,
Total Employee Involvement,
The Shingo Institute
on
November 26 , 2014.
Overproduction
Not wishing to rub salt in the wounds of my beleaguered Red Sox, their meteoric rise from last place in 2012 to first place in 2013 and subsequent..
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lean,
old lean dude,
six sigma,
continuous improvement,
kaizen,
overproduction,
gemba,
toyota production system,
seven wastes,
shigeo shingo
on
September 25 , 2014.
Can't See
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,..
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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.
Cracked
According to the USDA Egg Grading Manual, “Checks [aka ‘cracks’] are an unavoidable problem in the marketing of eggs because eggs cannot be..
This entry was posted in
old lean dude,
AQL,
NE Shingo Conference,
standards,
quality control,
bruce hamilton,
shigeo shingo,
defects
on
September 06 , 2013.