Facilitator guide
Case objectives, demonstration plans, debriefs, common mistakes and application checks across all 81 workplace cases and method lessons.
Download Facilitator guide PDF · 166 pages · 65.1 MBLean flow and system performance
Understand how the methods relate before selecting a detailed lesson.. Follow the visual, practise a decision, then check your thinking.
Fictional teaching examples and AI-generated illustrations. Proposed changes and goals are not achieved results. Use the written instructions and check local conditions before applying a method.
Connect demand, flow and the system constraint
Begin with required good output and the route that delivers it. A fast local step can still create waiting or excess WIP elsewhere. Relate demand to available working time, then choose how adjacent processes connect. Reliable methods and quality support this connection. In parallel, test what limits the system goal; a large queue alone does not prove the constraint. Align release and supporting work to that evidence. Check delivery, quality, WIP and workload together before expanding a change. Lean flow questions and TOC constraint questions can support the same investigation while retaining their distinct controls.
Follow the method
- Customer need: Required good output and timing
- See the whole route: Work, waiting and information
- Set the pace: Takt and a realistic release rhythm
- Connect the work: Flow, bounded FIFO or replenishment pull
- Reliable execution: Standard work, ready resources and quality
- Constraint focus: Protect the limiting system capability
- Measure the result: Delivery, WIP, quality and workload
- Learn and adjust: Test the whole-system effect
Read the example carefully
Takt is a demand reference; it is not a measured cycle time.
Flow, FIFO and supermarket pull require different operating conditions.
The constraint hypothesis requires route and operating-state evidence, not queue size alone.
Try it before revealing the answer
A team proposes speeding an upstream step while downstream work waits for missing information. Where does the map send the team first?
Reveal the answer and reasoning
Observe the complete route and the cause of downstream waiting. Test the constraint hypothesis and information readiness before assuming that upstream speed will improve delivery.
Pull signals, replenishment and a levelled release
Two kanban signals authorize different actions. A withdrawal signal permits movement of the specified item; a production signal permits its replacement. Keep the physical item route visually separate from the information route. Replenishment stock and signal quantities depend on actual demand, replenishment time, variation and policy; this overview prescribes no count. A levelled production release can organize mix and pitch where the process has the necessary capability. It does not mean every arriving order is produced immediately or that changeovers disappear. Quality at source, reliable replenishment and safe changeover improvement make smaller controlled releases more practical. Investigate missing or late signals rather than silently producing extra stock.
Follow the method
- Customer consumption: Actual need at the downstream process
- Withdrawal signal: Authorize the specified movement
- Supermarket: Controlled stock with clear identity
- Downstream use: Receive and use the required item
- Production signal: Authorize replacement of what was withdrawn
- Upstream production: Make the specified replacement
- Replenish stock: Restore the authorized item and quantity
- Levelled release: Manage mix and pitch where feasible
- Reliable conditions: Quality, changeover capability and replenishment time
Read the example carefully
Withdrawal authorizes movement; production kanban authorizes replacement production.
Pitch combines takt with a chosen pack quantity; a levelled mix requires feasibility checks.
Stock and signal quantities need local evidence; the drawing prescribes no universal number.
Try it before revealing the answer
A downstream team needs material and sends a withdrawal signal. Does that signal alone authorize an upstream operator to produce any convenient batch?
Reveal the answer and reasoning
No. The withdrawal signal authorizes the specified movement. Upstream production follows the appropriate production authorization, identity and quantity. Investigate a missing signal instead of substituting an unapproved batch.
Focus the constraint and control work release
Begin with the system goal and test what limits it. Protect useful existing capacity before assuming that investment is the first answer. Align upstream release, supporting work and local rules with that decision. In a drum-buffer-rope design, the drum provides the controlling schedule, the buffer protects a commitment and the rope controls release. Buffers do not justify arbitrary excess WIP or unsafe acceleration. Review actual disruption and delivery evidence to improve reliability. If further capacity remains necessary, evaluate elevation with the whole-system effect in view. Reidentify the current constraint after change; the previously slowest operation may no longer deserve the same priority.
Follow the method
- System goal: Demand for useful completed work
- Constraint evidence: Observe route, states and policies
- Exploit: Protect useful existing capability
- Subordinate: Align other work and local rules
- Drum: Schedule the controlling operation
- Buffer: Protect the commitment against disruption
- Rope: Release work to the agreed rule
- Review and elevate: Add capability if still needed
- Reidentify: Avoid inertia after improvement
Read the example carefully
DBR elements serve distinct functions: schedule, protection and release.
Buffer response requires a declared local policy; no universal color thresholds are supplied.
Exploitation and subordination may change the constraint before investment is needed.
Try it before revealing the answer
An upstream machine is idle while the controlling operation is fully supplied. A supervisor wants to release more work to improve local utilization. What should be checked?
Reveal the answer and reasoning
Check the drum schedule, authorized release rule, buffer condition and actual system demand. Extra upstream work may add WIP without improving delivery. Local utilization alone does not establish a valid release.
Sources and further reading
- Toyota Production System ↗
TPS purpose, people, jidoka and synchronized Just-in-Time
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Supplement to Learning to See ↗
FIFO work release and bounded queues in service workflows
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Supermarket ↗
Predetermined stock locations and consumption-triggered replenishment
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Takt Time ↗
Demand-paced time; page retrieved initially, subsequent request timed out
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - TOCICO: Introduction to TOC ↗
Define system goal/metrics, constraints and rules before intervention; public synopsis only
Public course synopsis only; no claim to have viewed restricted course content. - TOCICO: Process of Ongoing Improvement ↗
Five focusing steps connect applications and complement other improvement approaches; public synopsis only
Public course synopsis only; no claim to have viewed restricted course content. - LEI: Kanban ↗
Production and withdrawal signals authorize different actions
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Heijunka Box ↗
Mix/volume leveling, pitch = takt × pack quantity
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - LEI: Single Minute Exchange of Die ↗
Separate internal/external setup then convert and improve
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - TOCICO: Five Focusing Steps, 2013 ↗
Identify, exploit, subordinate, elevate, repeat without inertia
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - Goldratt Japan: Drum Buffer Rope ↗
Constraint schedule, protection and release control; English synthesis from Japanese primary text
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results. - TOCICO: Buffer Management ↗
Buffer management and recurring red-zone instability; indexed conference text
Method reference; original OPEX scenario and diagram are synthetic teaching content, not source case results.
Take the lesson into your team.
Read the lessons online or use these PDFs to prepare, practise and review with your team. No sign-in needed.
Learner workbook
Printable case worksheets, blank observation records and five calculation exercises; answers are separate.
Download Learner workbook PDF · 169 pages · 10.7 MBAnswer key and coaching notes
Reasoned sample responses, worked calculations and coaching guidance; fictional examples are clearly labelled.
Download Answer key and coaching notes PDF · 105 pages · 8.5 MBMethod and application reference
The native method mechanisms and worked applications for all 68 detailed lessons, in a separate bookmarked portrait reference.
Download Method and application reference PDF · 141 pages · 10.2 MBIllustrated systems atlas
Five illustrated system chapters: 15 Flare concept maps and 26 original workplace teaching cards, with links to all 81 supporting cases and method lessons.
Download Illustrated systems atlas PDF · 69 pages · 55.8 MBPractise the methods in this system.
- Explain how customer need, reliable work and release decisions form one delivery system.
- Distinguish work movement from the signals that authorize withdrawal and replenishment.
- Connect constraint evidence, useful capacity, protected commitments and release discipline.
TPS: people, quality and synchronized flow
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Muda, mura and muri reinforce each other
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Takt, cycle time and lead time are different
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Batch transfer versus one-piece flow
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Production and withdrawal kanban
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Office pull: capacity, blocked work and aging
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Heijunka mix and pitch release
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Connect processes: flow, bounded FIFO or supermarket
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Standardized work: sequence, takt and standard WIP
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Manual, walking and machine time
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Yamazumi: movable elements and constraints
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →SMED: externalize safely, verify first good output
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Replenishment stock: lead time and uncertainty
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →PFEP to point-of-use replenishment
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →TOC five focusing steps
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Find the constraint: evidence, not the biggest queue
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Drum-buffer-rope: schedule, protect, release
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Buffer management: priorities and recurring causes
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Throughput versus local utilization
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Critical chain: dependencies, resources and buffers
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Lean and TOC: complementary questions, distinct controls
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Shorten the handoffs
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Give the request a clear next step
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Keep the assembly line ready for the next frame
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →A clearer start for every cut order
Primary teaching mechanism belongs to lean flow and system performance. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Jidoka and andon: detect, respond, verify restart
Primary teaching mechanism belongs to quality control and dependable evidence. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Poka-yoke: prevention versus detection
Primary teaching mechanism belongs to quality control and dependable evidence. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Make tomorrow ready
Primary teaching mechanism belongs to leadership and daily learning. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Shine and sustain: evidence over time
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Operator care and specialist maintenance
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Planned maintenance: criticality to verified return
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →OEE loss waterfall with denominator discipline
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Quality maintenance: control conditions, not just inspect output
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Find it. Use it. Reset it.
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →A tool room ready for the next job
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →Give the press area a clear reset
Primary teaching mechanism belongs to equipment wellness and oee. Supporting links identify application dependencies; they do not make the methods interchangeable.
Explore the connected method →