Lean Production Simplified, Third Edition: A Plain-Language Guide to the World's Most Powerful Production System

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 Ford Explains the concepts of visual management, Five S, and Total Productive Maintenance Addresses just-in-time delivery of parts and products Examines the jidoka principle Covers the nervous system of Lean management, hoshin planning Illustrates 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.

Table of Contents:
The Birth of Lean Craft Production Mass Production Ford System Other Developments Growing Dysfunction Worker Alienation Quality Machinery Engineering Birth of Lean Production Historic Bargain A Novel Concept A Virtue of Necessity Completing the Lean Revolution at Toyota Summary Reference Endnotes Study Questions Lean Production System Why Lean Production? New Economics Systems and Systems Thinking The "Thinking Way" Basic Image of Lean Production Customer Focus Muda Motion Delay Conveyance Correction Overprocessing Inventory Overproduction Knowledge A Word of Caution Mura Muri Summary Endnotes Study Questions Stability Lean System Standards Visual Management 5S System S1—Sort S2—Set in Order S3—Shine (and Inspect) S4—Standardize S5—Sustain Total Productive Maintenance Key Measures Six Big Losses The Machine Loss Pyramid Small-Group Activity Summary Endnotes Study Questions Standardized Work Methods Engineering versus Lean Thinking What Do We Have to Manage? Maximize Utilization of Machines or People? Labor Density Why Standardized Work? Prerequisites for Standardized Work Elements of Standardized Work Takt Time Takt Time and Cycle Time Work Sequence In-Process Stock Charts Used to Define Standardized Work Production Capacity Chart Manpower Reduction Overall Efficiency Versus Individual Efficiency Standardized Work and Kaizen Guidelines for Economy of Motion Guidelines for Layout and Equipment Guidelines for Tools and Jigs Common Layouts Islands Connected Islands Connected Islands with Full-Work Control Cells Summary Endnotes Study Questions Just-in-Time Production Why JIT? Basic Principles of JIT Continuous Flow Pull The JIT System Kanban Kanban Metaphors Pacemaker Process The Store Six Kanban Rules Expanded Role of Conveyance How Frequently Should We Provide Production Orders? Quick Adjustment to Demand Changes or Other Sources of Instability Better Sense of Takt Time Fewer Peaks and Valleys Abnormality Control Two Kinds of Conveyance Production Leveling Responding to Changes in Customer Demand Heijunka Box Three Types of Pull Systems Type A Pull System Type B Pull System Type C Pull System Value Stream Mapping Summary Endnotes Study Questions Jidoka Development of the Jidoka Concept Why Jidoka? How to Improve Human Reliability Poka-Yoke Common Errors Inspection Systems and Zone Control Judgment Inspections—Discovering Defects Informative Inspections—Reducing Defects Source Inspections—Preventing Defects Vertical Source Inspections Horizontal Source Inspections Using Poka-Yokes Two Types of Action Three Paths to Poka-Yoke Poka-Yoke Detection Methods Implementing Jidoka Annual Jidoka Strategy and Goals Future Directions Summary Endnotes Study Questions Involvement Why Involvement? Terrible Waste of Humanity Activities Supporting Involvement Goal of Involvement Kaizen Circle Activity Structure of KCA KCA Training KCA Administration KCA Promotion Role of the Manager Practical Kaizen Training Key Factors for PKT Success Communication Grasping the Situation Problem Solving Role of the Supervisor Suggestion Programs Hassle-Free Process and Clear Rules Tangible Suggestions Intangible Suggestions Quick Decision-Making and Feedback Fairness Promotion Extrinsic and Intrinsic Motivation How to Motivate Suggestions Quantity First—Then Quality Annual Culture Hoshin Summary Endnotes Study Questions Hoshin Planning What Is Planning? Why Plan? Problems with Planning How Do We Create Flow? Hoshin Planning Focus of Hoshin Planning Alignment and Flexibility Hoshin Planning System PDCA Check Outcomes and Process Strengthen People Nemawashi Catchball The Control Department17 Concept A3 Thinking History of Report Writing Common Report-Writing Problems The Four Phases of Hoshin Planning Hoshin Generation Hoshin Deployment Output of Hoshin Deployment Hoshin Implementation Hoshin Evaluation Book of Knowledge Summary Endnotes Study Questions The Culture of Lean Production What Is Lean Culture? PDCA Grasping the Situation Plan Do Check Act Reflection—Breakfast of Champions Warm Heart Principle Standardization Standards and Abnormality Control Visual Management Teamwork Paradox Intensity Lean Production as a Path How Does Lean Culture Feel? Summary Final Comments Endnotes Study Questions Appendix A: Glossary Appendix B: Bibliography

About the Author :
Pascal Dennis, P.Eng, M.Eng., is a professional engineer, author, and president of Lean Pathways, an international consultancy. Pascal developed his skills on the Toyota shop floor in North America and Japan and by working with major international companies. Winner of four Shingo Prizes for Excellence, Pascal has supported breakthrough improvement in healthcare, software development, financial services, construction, and the consumer goods and process industries. The focus of his practice is strategic planning and execution, executive coaching, and growing intellectual capital. Pascal is the author of several award-winning books including Andy & Me, Getting the Right Things Done - A Leader’s Guide to Planning & Execution, and The Remedy - Bringing Lean Out of the Factory to Transform the Entire Organization.

Review :
"There is a need for a book exactly like this, and Pascal has the experience, knowledge, and passion to write it. Pascal Dennis is one of many Westerners who, during the past 20 years, have gained firsthand experience with `Lean production’ or the Toyota Production System (TPS). At Toyota Motor Manufacturing Canada, one of Toyota’s early and successful efforts to transplant TPS outside the confines of Toyota City in Japan, Pascal received personalized mentoring from his trainer from Toyota City about each of the processes, systems, and philosophies explained in this book." —John Shook, Senior Advisor, Lean Enterprise Institute; President, TWI Network, Inc., Ann Arbor, Michigan, USA Praise for the Shingo Prize-Winning Second Edition: "Lean Production Simplified is both enlightening and informative for all levels of `Lean learners.’ It is written from a very human perspective. Many prior publications focus on the `Lean bag of tools’ or the softer cultural aspects of Lean. Dennis' contribution is a well integrated blend of both giving the reader not only a systemic understanding of Lean, but also the clear skill development required for leadership at all levels. Wherever you are on your journey to Lean, Lean Production Simplified will provide further knowledge and insight to help achieve the next level on the eternal path to perfection." —Anne Stevens, VP, North America Vehicle Operations, Ford Motor Company "This book is just too important! In this age of global competition threatening to annihilate all but the very Leanest, Pascal Dennis' masterwork, Lean Production Simplified: A Plain-Language Guide to the World's Most Powerful Production System, is a must-read. Midway through my career, after working at five large North American manufacturing companies, it's absolutely crystal clear that the three which `died’ would have survived if only they'd known of and successfully implemented The Toyota Production System." —Michael A. J. Davis, Executive VP, Waterville TG, Inc. "Lean Production Simplified goes beyond being a `primer’ for the Toyota Production System - it is `Lean thinking’ at its best, revealed and explained. Pascal Dennis has drawn from his own experience at Toyota to help the reader understand the meaning behind their language of success, with the why's and how's explained clearly with illustrations that include the very forms used to collect and organize data. Be prepared to have your continuous improvement/people skills honed to a higher level. Whether you're a CEO, president, vice president, manager, supervisor, leader, engineer, HR specialist, employee, or a private owner, Lean Production Simplified is not a book you will read once. It's a book you will read once and then use as a reference book to read and re-read again and again, as its content is absorbed into your area of influence." —Bob Schroer, Lean Change Agent, Lexington, Ohio