MR LEAN BUYS AND TRANSFORMS A MANUFACTURING COMPANY

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Mr Lean Buys And Transforms A Manufacturing Company

Author : Greg Lane
ISBN : 9781439815175
Genre : Business & Economics
File Size : 75.20 MB
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This is the true story of how, armed with only Lean improvement methodologies, a specially trained Toyota Lean expert purchased a business he knew nothing about, applied Lean techniques, and succeeded in doubling sales and increasing profitability, before he finally sold the thriving business. With humility and humor, the author recounts his successes and failures, introduces his key employees and their struggles with change, and provides motivation and simple ideas for all readers looking to improve their businesses. He captures key points highlighted in text boxes and includes illustrative photos and examples of Lean tools at work. This story dispels the fallacy that Lean management does not achieve excellent results in high variation companies and job shops. Toyota’s OSKKK methodology is introduced to understand processes and guide a Lean transformation on the shop floor and in the office.
Category: Business & Economics

Toyota By Toyota

Author : Samuel Obara
ISBN : 9781439880753
Genre : Business & Economics
File Size : 45.81 MB
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Written by former Toyota associates, Toyota By Toyota: Reflections from the Inside Leaders on the Techniques That Revolutionized the Industry focuses on the purpose of Lean methodologies, techniques, and principles. It compiles more than a century of combined experience from management-level employees who supply little-known insights about the Toyota Production System (TPS)—featuring many who worked directly with Taiichi Ohno. The book illustrates experiences at Toyota locations around the world, including the United States, Brazil, Venezuela, Europe, and Japan. Associates from various divisions, including sales, training, logistics, manufacturing, and human resources, provide diverse points of view regarding the application of the Lean principles discussed. In each chapter, TPS experts: Share their story about when and how they learned the specific Lean technique, methodology, or concept Describe the Lean technique, along with its benefits and pitfalls Supply helpful implementation tips A common thread that weaves these stories together is that each contributor had to learn their lessons the hard way. Although there is no magical, painless way to learn Lean, the authors hope that by sharing their experiences and struggles, you can avoid having to struggle through the same lessons. Readers will benefit from seeing the various approaches used to teach, as well as the unique way these authors translate that learning to the reader.
Category: Business & Economics

Made To Order Lean

Author : Greg Lane
ISBN : 1563273624
Genre : Business & Economics
File Size : 67.29 MB
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Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs. About the author: Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS. He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales. Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: [email protected]
Category: Business & Economics

Applied Lean Business Transformation

Author : Dennis P. Hobbs
ISBN : 9781932159790
Genre : Business & Economics
File Size : 70.50 MB
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This volume presents a holistic business improvement strategy that targets the right resources and implementation methodologies to the right opportunities that many firms are missing. It shows how to integrate kaizen, lean and six sigma into an improvement initiative across the entire company.
Category: Business & Economics

Andy Me Second Edition

Author : Pascal Dennis
ISBN : 9781439884058
Genre : Business & Economics
File Size : 67.97 MB
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Second Edition of a Shingo Prize Winner Based on the author's personal experience with Toyota’s master teachers and with companies in the midst of great change, Andy & Me: Crisis & Transformation on the Lean Journey, now in its second edition, is a business novel set in a failing New Jersey auto plant focusing on the tribulations of Tom Pappas, the plant manager. The situations, characters, and plant politics will ring true with many readers. In a cool, readable style, this highly popular work follows Tom's relationship with Andy Saito, a reclusive retired Toyota guru whom Tom persuades to help save his plant through the teaching of the legendary Toyota Production System (TPS). On this journey, the reader learns that TPS is more than just a collection of tools; it entails a new way of thinking and behaving. Though Tom finds success — both in his plant and in his personal life — he learns from Andy that successful improvement is endless and eternal.This edition includes study questions after each chapter to support your learning and help you tell some of your own stories. Pascal Dennis discusses the 2nd edition of his Shingo Prize-winning book Andy & Me.
Category: Business & Economics

Lean Transformation

Author : Bruce A. Henderson
ISBN : 1511657030
Genre : Industrial efficiency
File Size : 62.27 MB
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Known worldwide in manufacturing among those striving to maximize productivity and create pull scheduling of production as "the yellow book," this is the premier how to book for companies going lean. Touted by experts everywhere as practical, down-to-earth, and easy to read, it warns of cultural issues that are certain to arise, and gives step by step instructions for making the transformation. It clearly explains such tools as continuous flow, value stream mapping, kanban, kaizen, six sigma, just-in-time (JIT), techniques for quick set-ups, and other pillars of the Toyota Production System. It's full of examples of value stream mapping, how kanban can resolve material supply issues, how kaizen brainstorming can result in startling improvements overnight, how just-in-me (JIT) frees mountains of money tied up in work-in-progress, why Six Sigma quality needs to be built in and not inspected in, how bottlenecks can be eliminated, kanban snafus spotted before they happen, and how instilling a championship mentality in cross-functional teams an lead to increased productivity and continuous improvement that doesn't stop after the initial kaizen event.
Category: Industrial efficiency

Claves Del Lean Management En Tiempos De Maxima Competitividad

Author : Lluís Cuatrecasas Arbós
ISBN : 9788416583041
Genre : Business & Economics
File Size : 42.85 MB
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Claves para una economía y unas finanzas más responsables, personalizadas y alejadas del despilfarro. La reciente crisis ha sido el resultado de un modelo de gestión implantado desde inicios del siglo pasado, que ha llevado al mundo a un consumo desbocado y a generar burbujas, malgastando recursos facilitados por las entidades financieras, sin aplicar el necesario control. Como consecuencia de estas prácticas inadecuadas, el consumo ha acabado cayendo espectacularmente y los recursos financieros se han vuelto mucho más difíciles de obtener. Para no caer en los mismos errores, hay que cambiar definitivamente de paradigma y olvidarse de generar productos y servicios a gran escala, despersonalizados y que no tienen en cuenta las preferencias de los clientes. Nuevos enfoques, para los que la eficiencia y la innovación forman parte esencial de su ADN, están ya introduciéndose desde hace unos años y las empresas que operan de acuerdo con ellos están obteniendo magníficos resultados. Este es el camino que las empresas deben emprender ahora y en el futuro.
Category: Business & Economics

Lean Production For The Small Company

Author : Mike Elbert
ISBN : 9781439877791
Genre : Business & Economics
File Size : 73.77 MB
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A hands-on guide to adapting Lean principles and the Toyota Production System to high-mix/low-volume environments, Lean Production for the Small Company uses charts, pictures, and easy-to-understand language to describe the methods needed to improve processes and eliminate waste. It walks readers through the correct order of implementation and describes problems and pitfalls along with time-tested solutions. Explaining how to incorporate existing systems into a Lean strategy, the book starts with the fundamentals and builds on them to describe the full range of tools and processes needed to implement Lean. It outlines how to design factories for Lean manufacturing and demonstrates how to remove variations within business and manufacturing processes to achieve a smooth continuous flow of product that delivers your product on time to customers. The tools, methods, and ideals discussed are applicable in any industry and all parts of your business—from manufacturing and sales to human resources. The text unveils new methods and tools that can help you reduce inventory, improve inventory turns, and facilitate raw material flow through the factory. It details how to use customer order demands to schedule the production floor, rather than using estimated production schedules. It also considers the accounting process and explains how to improve your cash-to-cash cycle time. Drawing on the author’s decades of experience transforming high-mix plants to Lean, the text brings together coverage of the tools and processes that have made Toyota so successful. All the chapters in this book, when implemented, will result in a culture change that will transform your company into a learning organization that continuously eliminates waste and improves its processes.
Category: Business & Economics

Liquid Lean

Author : Raymond C. Floyd
ISBN : 9781439888483
Genre : Business & Economics
File Size : 90.49 MB
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While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author’s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of the problem is resistance to transformational change, a barrier that can only be overcome with effective leadership and results-oriented planning that engages rather than excludes all stakeholders. Winner of a 2012 Shingo Prize! Written by Raymond Floyd, an unparalleled leader of Lean transformations, Liquid Lean: Developing Lean Culture in the Process Industries provides potential process industry change agents with the no-nonsense guide needed to eliminate waste and achieve sustainable optimal efficiency. Presenting lessons in lean as they apply within the liquid industries, the book focuses on developing the four measures of Lean as defined by the Shingo Award: Business Results Consistent Lean Enterprise Culture Continuous Process Improvement Cultural Enablers Illustrated with his own success stories, Floyd describes business results, Lean enterprise thinking, and policy deployment in process industry terms. He offers detailed theory, practice, and examples of continuous process improvement, and describes the leadership and defines the ethics needed to evolve and sustain Lean transformation. Floyd lays out the specific steps needed during the first six months of transformation and the benchmarks to be achieved during the first two years of implementation. All companies can benefit from Lean; this book makes sure that those who want it, know how.
Category: Business & Economics

Lean Human Resources

Author : Cheryl M. Jekiel
ISBN : 9781439813072
Genre : Business & Economics
File Size : 23.81 MB
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Encouraging a long overdue shift in thinking, this book gives managers and executives the means to maximize employee potential by first showing them how to increase the improvement power of their HR departments. Cheryl M. Jekiel, who has been implementing Lean initiatives out of HR offices for 20 years, defines the people-related approaches and practices needed to alter any cultural dynamic that keeps employees from leveraging their peak abilities. She looks at why so many companies allow this sort of waste to exist, how traditional HR departments have not been especially effective in combating waste, and why today’s HR department should be seen differently, as a partner delivering exceptional customer service to employees. Everyone Needs to Learn and Improve Everyone Needs to Participate and Be Involved Ultimately, lasting change requires evolution in an organizational cultural and to achieve such change requires definitive changes in behavior. To ensure that changes are properly paced and effectively put into operation, the book puts forth a proven five-year plan that includes the building of improvement-linked competencies into each job. Everyone Can Lead Lead with the Customer in Mind Lead by Teaching and Coaching Lead by Creating More Leaders A final section is designed especially for CEOs who must address their own views of HR before addressing improvement. They must recognize that Lean HR strategies and methods can be used to create a highly motivating place to work, and that anything less would be a waste of talent. To begin, an organization must realize the value of its HR staff and put it to use implementing improvement that is organic, fundamental, and self perpetuating.
Category: Business & Economics