Process Management: practical guides, worked calculations and shop-floor examples. Browse every article in this topic and start with the main guide.
Theory of Constraints (TOC): Bottleneck, 5 Steps, Example
Learn the Theory of Constraints: what a bottleneck is, the five focusing steps, drum-buffer-rope and a worked example…
Hoshin Kanri: Strategy Deployment, Catchball and Example
Understand hoshin kanri: how to deploy strategy, catchball, the X-matrix and a worked example that cuts lead time fro…
ISO 9001 Implementation and Certification: A Step-by-Step Guide
ISO 9001 explained: clauses 4 to 10, step-by-step implementation, a gap analysis example, certification audits (stage…
Value Stream Mapping (VSM): How to Map, Steps and Example
Learn value stream mapping with a worked example: current state map, lead time, takt time, process cycle efficiency,…
MRP: how to calculate material requirements, with an example
Learn MRP with a worked example: bill of materials, gross and net requirements, lead time offsetting and planned orde…
Learning curve: formula, example and how to use it
Understand the 80% learning curve, the formula Tn = T1 × n^b, a worked example from unit 1 to 16, the chart and where…
Queuing theory: the M/M/1 model with a worked example
Learn queuing theory with the M/M/1 model: arrival and service rates, utilization, customers in queue, waiting time a…
ABC inventory analysis: how to classify your stock items
Learn ABC inventory analysis with a 10-item example: annual value, cumulative percentage, A, B and C classes, and how…
Time study: how to calculate standard time with an example
Learn time study step by step: readings, performance rating, normal time, allowances, standard time, number of cycles…
Demand forecasting: moving average and exponential smoothing
Learn demand forecasting with an example: 3-month moving average, exponential smoothing with alpha 0.3, MAD forecast…
Job sequencing rules: FIFO, SPT and EDD compared
Compare the FIFO, SPT and EDD job sequencing rules with a 4-job example, Gantt charts, average flow time, total tardi…
Facility layout types: the 4 layouts and when to use each
Learn the facility layout types: fixed-position, process, cellular and product layout, the volume and variety matrix,…
SIPOC diagram: how to build one, with an example
Learn how to build a SIPOC diagram with a plastic injection molding example, what each letter means, the steps, when…
Lead time: what it is, how to calculate it and how to cut it
Lead time from order to delivery explained: types of lead time, a worked calculation, Little's Law, lead time vs…
Critical path method (CPM) and PERT: a worked example
Learn the critical path method and PERT with a worked example: activity network, early and late start and finish, tot…
Linear programming and the simplex method: a worked example
Understand linear programming with a product-mix example: model, constraints, graphical method, simplex, optimal solu…
Assembly line balancing: how to calculate it with takt time
Learn how to balance a production line with takt time, the minimum number of workstations, task assignment, line effi…
Industry 4.0 in manufacturing: technologies and how to start
Understand Industry 4.0: its origins, the technology pillars, a real-time OEE example, how it relates to Lean and a 5…
Production planning and control: MPS, MRP and scheduling explained
Production planning and control in practice: planning levels, S&OP, the master production schedule, an MRP exampl…
Inventory management: reorder point, safety stock and EOQ
How to calculate reorder point, safety stock and economic order quantity, with a worked example, ABC analysis, turns,…
SMED: How to Cut Changeover Time (Setup)
Understand the SMED (Single-Minute Exchange of Die) method, the difference between internal and external setup, and a st…
Standardized Work: What It Is and Why It's the Foundation of Lean
Understand what standardized work is, its 3 elements, and why it's considered the foundation for any sustainable continu…
Visual Management: How to Use Boards and Metrics on the Shop Floor
Understand the principles of visual management, the most common board types (production, metrics, 5S), and how to avoid …