The 4 rules of lean thinking

In the article :Decoding the DNA of the Toyota Production System, Steven Spear captures 4 rules that summarize the operating principles of the Toyota Production System. These rules are very powerful at the moment you are faced with challenges trying to improve a process. When you face these type of problems, STOP and reflect on the 4 rules, you will be able to find a solution to your problem.

Rule 1

All work should be highly specified as to CONTENT, SEQUENCE, TIMING and OUTCOME.
can you clearly explain this for elements on your job? if the answer is not, then you have an opportunity for improvement.

Rule 2

Every customer supplier connection must be DIRECT and there must be an unambiguous YES-OR-NO way to send the requests and receive responses
Again the same question applies, can you clearly describe these two elements in your customer-supplier connections? if not, then you have an opportunity for improvement

Rule 3

The pathway for every product and service must be simple and direct

Rule 4

An improvement must be made in accordance with the scientific method, with guidance, and as close as possible to the actual work.

Advantages of 5S

Some peole have recently asked me to provide some specific advantages of a 5s program.

I have said before that the main purpose is to make problems and opportunities for improvement visible, but there are other benefits as well and these are:


•Raises Employee Morale
•Better Safety
•Great "Effort/Impact" relationship
•Establishes baseline for the lean journey
•Better use of time and talent
•Better use of physical resources
•Better understanding of processes and relationships
•Improved communications
•Lowered Stress

Catchy phrases for 5S implementation

These phrases could help you when implementing 5S

for Sort:
when in doubt throw it out

for Set in order:
A place for everything and everything in its place

for Shine:
Seen through the eyes of an important visitor

for Standardize:
Sort, straighten, and shine always

for Sustain:
Make 5S a habit

The following video shows a great way to explain 5S

Another definition of 5S

5S is a continuous improvement program for maintaining a visual workplace utilizing a 5-step process for identifying and eliminating hidden wastes through effective workplace organization, visual communication and general cleanliness.

Quotes on lean thinking and leadership

No mistake is fatal unless you make it so

Quotes on lean thinking and time management

The wise do only what needs to be done.

A fool and his inventory are never parted

Definition of Kanban

Kanban is a card or sheet used to authorize production or movement of an item; when fully implemented, kanban (the plural is the same as the singular) operate according to the following rules:

1. all production and movement of parts and material take place only as required by a downstream operation, i.e. all manufacturing and procurement are ultimately driven by the requirements of final assembly or the equivalent.

2. the specific tool which authorizes production or movement is called a kanban. The word literally means card or sign, but it can legitimately refer to a container or other authorizing device. Kanban have various formats and content as appropriate for their usage; for example, a kanban for a vendor is different than a kanban for an internal machining operation.

3. The quantity authorized per individual kanban is minimal, ideally one. The number of circulating or available kanban for an item is determined by the demand rate for the item and the time required to produce or acquire more. This number generally is established and remains unchanged unless demand or other circumstances are altered dramatically; in this way inventory is kept under control while production is forced to keep pace with shipment volume. A routine exception to this rule is that managers and workers are continually exhorted to improve their processes and thereby reduce the number of kanban required.