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The Lean Toolbox

The Lean Toolbox


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About the Book

The Lean Toolbox is the essential quick reference guide to the concepts and techniques of lean operations and the lean enterprise. This second edition incorporates new and updated sections. Large-multiple copies of the first edition were acquired by, amongst others, Ford Motor Company, Delphi Automotive, the Welsh Development Agency, British Steel, and Rolls Royce Allison. Many consultancies acquired multiple copies and the book was used on programs run at the universities of Cambridge, Cardiff, Cranfield, Warwick, and Ashridge. Chapters include: Philosophy; Planning; Design and New Products; Analysis and Mapping; Improvement; Production; Goldratt; Quality; Suppliers and Distribution; People; Measurement.

Table of Contents:
Philosophy: lean thinking; 14 characteristics of lean; agile operations; the elements of agility; time based competition; muda; the sustainable lean enterprise and the R's of lean; gemba. Planning: scenarios; time pacing; value focused thinking; policy deployment and cross functional management; target costing. Design and new products: development time and organizing for new products; four objectives and six trade-offs; simultaneous and concurrent engineering; mass customization and modularity; design for manufacture; product platforms; four fields mapping; quality function deployment; TRIZ; concept screening. Analysis and mapping: takt time; system dynamics, systems thinking, and learning; product contributions analysis; the Muda map; storyboarding and brown paper exercise; value stream mapping; time charting and analysis; soft systems methodology; self audits. Improvements: continual improvement; 5S; kaikaku; standards; string diagrams; value engineering and value analysis; kaizen; total productive maintenance (TPM); overall equipment effectiveness (OEE); root cause analysis; business process reengineering (BPR). Production: little's law; kanban; batch sizing; changeover reduction; mixed model production; runners, repeaters, strangers; demand smoothing (Heijunka); group technology and cellular manufacturing; inventory issues: cost, waste, safety stocks; visual and audio management; point of production control. Goldratt: throughput, inventory, operating expense; dependent events, statistical fluctuation; constraints, bottlenecks and the synchronous rules; drum, buffer, rope; theory of constraints and thinking process. Quality: the Kano model; failsafing (pokayoke); short run SPC; precontrol. Suppliers and distribution: supplier partnerships; supplier associations; integrated supply. People: open book management; meeting, memos and responsibilities; change management; ubuntu and kyosei. Measurement: management accouting and activity based costing; Kaizen costing and pseudo profit centres; performance measurement and the balanced scorecard; productivity accounting.


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Product Details
  • ISBN-13: 9780951382998
  • Publisher: Picsie Books
  • Publisher Imprint: Picsie Books
  • Edition: Revised edition
  • Width: 210 mm
  • ISBN-10: 0951382993
  • Publisher Date: 02 Jan 2000
  • Binding: Paperback
  • Height: 230 mm


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