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Lean Production Simplified, Third Edition: A Plain-Language Guide to the World's Most Powerful Production System (3rd New edition)

Lean Production Simplified, Third Edition: A Plain-Language Guide to the World's Most Powerful Production System (3rd New edition)

By: Pascal Dennis (author)Paperback

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Description

Following in the tradition of its Shingo Prize-winning predecessors, Lean Production Simplified, Third Edition gives a clear overview of the structure and tools of the Lean production system. Written for the practitioner by a practitioner, it delivers a comprehensive insider's view of Lean management. The author helps readers grasp the system as a whole, as well as the factors that animate it, by organizing the book around an image of a house of Lean production. Illustrating the eight kinds of waste, this updated edition of a bestseller: Describes the craft and mass production systems that preceded Lean production-including the contributions of Frederick Winslow Taylor and Henry FordExplains the concepts of visual management, Five S, and Total Productive MaintenanceAddresses just-in-time delivery of parts and productsExamines the jidoka principleCovers the nervous system of Lean management, hoshin planningIllustrates the culture of Lean management This edition deepens and extends the previous edition with case studies on Lean outside the factory-in settings such as health care, IT, finance, design, engineering, and beyond. The case studies are based on personal experience of actual work in organizations generating real results.Lean Production Simplified, Third Edition covers each of the components of Lean within the context of the Lean production system. The author's straightforward common sense approach makes this book an easily accessible, on-the-floor resource for every team member. Watch Shingo Prize-winning author Pascal Dennis discuss Lean Production Simplified, Third Edition https://youtu.be/YD030vOb8KM

About Author

Pascal Dennis is President of Lean Pathways, an international coaching team. He is the author of four previous books on Lean management, all of which have won the prestigious Shingo Prize for outstanding research in the field of operational excellence. Pascal and his team have worked with major healthcare systems like Inova Health System, Baptist Memorial Healthcare Corporation, Health Sciences North and Salem Health, as well as Fortune 100 companies like Kimberly Clark and Lockheed Martin. Pascal learned the Toyota business system in leadership positions at Toyota Motor Manufacturing Canada, one of Toyota's best plants, and has worked with leading senseis in North America and Japan. Pascal lives in Toronto with his wife and three children. For more information please visit www.leansystems.org.

Contents

The Birth of LeanCraft ProductionMass ProductionFord SystemOther DevelopmentsGrowing DysfunctionWorker AlienationQualityMachineryEngineeringBirth of Lean ProductionHistoric BargainA Novel ConceptA Virtue of NecessityCompleting the Lean Revolution at ToyotaSummaryReferenceEndnotesStudy QuestionsLean Production SystemWhy Lean Production?New EconomicsSystems and Systems ThinkingThe "Thinking Way"Basic Image of Lean ProductionCustomer FocusMudaMotionDelayConveyanceCorrectionOverprocessingInventoryOverproductionKnowledgeA Word of CautionMuraMuriSummaryEndnotesStudy QuestionsStabilityLean System StandardsVisual Management5S SystemS1-SortS2-Set in OrderS3-Shine (and Inspect)S4-StandardizeS5-SustainTotal Productive MaintenanceKey MeasuresSix Big LossesThe Machine Loss PyramidSmall-Group ActivitySummaryEndnotesStudy QuestionsStandardized WorkMethods Engineering versus Lean ThinkingWhat Do We Have to Manage?Maximize Utilization of Machines or People?Labor DensityWhy Standardized Work?Prerequisites for Standardized WorkElements of Standardized WorkTakt TimeTakt Time and Cycle TimeWork SequenceIn-Process StockCharts Used to Define Standardized WorkProduction Capacity ChartManpower ReductionOverall Efficiency Versus Individual EfficiencyStandardized Work and KaizenGuidelines for Economy of MotionGuidelines for Layout and EquipmentGuidelines for Tools and JigsCommon LayoutsIslandsConnected IslandsConnected Islands with Full-Work ControlCellsSummaryEndnotesStudy QuestionsJust-in-Time ProductionWhy JIT?Basic Principles of JITContinuous FlowPullThe JIT SystemKanbanKanban MetaphorsPacemaker ProcessThe StoreSix Kanban RulesExpanded Role of ConveyanceHow Frequently Should We Provide Production Orders?Quick Adjustment to Demand Changes or Other Sources of InstabilityBetter Sense of Takt TimeFewer Peaks and ValleysAbnormality ControlTwo Kinds of ConveyanceProduction LevelingResponding to Changes in Customer DemandHeijunka BoxThree Types of Pull SystemsType A Pull SystemType B Pull SystemType C Pull SystemValue Stream MappingSummaryEndnotesStudy QuestionsJidokaDevelopment of the Jidoka ConceptWhy Jidoka?How to Improve Human ReliabilityPoka-YokeCommon ErrorsInspection Systems and Zone ControlJudgment Inspections-Discovering DefectsInformative Inspections-Reducing DefectsSource Inspections-Preventing DefectsVertical Source InspectionsHorizontal Source InspectionsUsing Poka-YokesTwo Types of ActionThree Paths to Poka-YokePoka-Yoke Detection MethodsImplementing JidokaAnnual Jidoka Strategy and GoalsFuture DirectionsSummaryEndnotesStudy QuestionsInvolvementWhy Involvement?Terrible Waste of HumanityActivities Supporting InvolvementGoal of InvolvementKaizen Circle ActivityStructure of KCAKCA TrainingKCA AdministrationKCA PromotionRole of the ManagerPractical Kaizen TrainingKey Factors for PKT SuccessCommunicationGrasping the SituationProblem SolvingRole of the SupervisorSuggestion ProgramsHassle-Free Process and Clear RulesTangible SuggestionsIntangible SuggestionsQuick Decision-Making and FeedbackFairnessPromotionExtrinsic and Intrinsic MotivationHow to Motivate SuggestionsQuantity First-Then QualityAnnual Culture HoshinSummaryEndnotesStudy QuestionsHoshin PlanningWhat Is Planning?Why Plan?Problems with PlanningHow Do We Create Flow?Hoshin PlanningFocus of Hoshin PlanningAlignment and FlexibilityHoshin Planning SystemPDCACheck Outcomes and ProcessStrengthen PeopleNemawashiCatchballThe Control Department17 ConceptA3 ThinkingHistory of Report WritingCommon Report-Writing ProblemsThe Four Phases of Hoshin PlanningHoshin GenerationHoshin DeploymentOutput of Hoshin DeploymentHoshin ImplementationHoshin EvaluationBook of KnowledgeSummaryEndnotesStudy QuestionsThe Culture of Lean ProductionWhat Is Lean Culture?PDCAGrasping the SituationPlanDoCheckActReflection-Breakfast of ChampionsWarm Heart PrincipleStandardizationStandards and Abnormality ControlVisual ManagementTeamworkParadoxIntensityLean Production as a PathHow Does Lean Culture Feel?SummaryFinal CommentsEndnotesStudy QuestionsAppendix A: GlossaryAppendix B: Bibliography

Product Details

  • ISBN13: 9781498708876
  • Format: Paperback
  • Number Of Pages: 223
  • ID: 9781498708876
  • weight: 454
  • ISBN10: 1498708870
  • edition: 3rd New edition

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