Lean Production Simplified: A Plain Language Guide to the World's Most Powerful Production System » (2nd Edition)

2006 SHINGO PRIZE WINNER for EXCELLENCE in MANUFACTURING RESEARCH

Lean Production Simplified, 2nd Edition is a plain language guide to the lean production system written for the practitioner by a practitioner. It delivers a comprehensive insider's view of lean manufacturing. The author helps the reader to grasp the system as a whole and the factors that animate it by organizing the book around an image of a house of lean production.

Highlights include:

A comprehensive view of Toyota¹s lean manufacturing system

A look at the origins and underlying principles of lean

Identifying the goals of lean production

Practical problem solving for lean production

Activities that support involvement - Kaizen circles, suggestion systems, and problem solving

This 2nd Edition has been updated with expanded information on the Lean Improvement Process; Production Physics and Little's Law - the fundamental equation for both manufacturing and service industries (cycle time = work in process/throughput); Value Stream Thinking - combining processes required to bring the product or service to the customer; Hoshin Planning — using the Planning and Execution Tree diagram and Problem Solving — including the "Five Why" method and how to use it.

Lean Production Simplified, 2nd Edition covers each of the components of lean within the context of the entire lean production system. The author's straightforward common sense approach makes this book an easily accessible on-the-floor resource for every operator.

Chapter 1: The Birth of Lean Production

Craft Production

The Mass Production System

The Growing Dysfunction

The Birth of Lean Production

The Historic Bargain

A Virtue of Necessity

Completing the Lean Revolution at Toyota

Chapter 2: The Lean Production System

Why Lean Production?

Systems and Systems Thinking

Basic Image of Lean Production

Customer Focus

Muda

Chapter 3: Stability

Standards in the Lean System

The Five S System

Total Productive Maintenance

Chapter 4: Standardized Work

Methods Engineering versus Lean Thinking

What Do We Have to Manage?

Why Standardized Work?

The Elements of Standardized Work

Charts Used to Define Standardized Work

Manpower Reduction

Overall Efficiency versus Individual Efficiency

Standardized Work and Kaizen

Common Layouts

Chapter 5: Just-In-Time

Why JIT?

Basic Principles of JIT

The JIT System

Kanban

The Six Kanban Rules

Expanded Role of Conveyance

Production Leveling

Three Types of Pull Systems

Value Stream Mapping

Chapter 6: Jidoka

Development of the Jidoka Concept

Why Jidoka?

Poka-yoke

Inspection Systems and Zone Control

Using Poka-yokes

Implementing Jidoka

Chapter 7: Involvement - The Wind That Fills the Sail

Why Involvement?

The Terrible Waste of Humanity

Activities Supporting Involvement

Kaizen Circle Activity

Practical Kaizen Training

Suggestion Programs

Chapter 8: Hoshin Planning

What is Planning?

Why Plan?

Problems with Planning

Hoshin Planning

Hoshin Planning System

The Four Phases of Hoshin Planning

Chapter 9: The Culture of Lean Production

What is Lean Culture?

How Does Lean Culture Feel?

Glossary Bibliography Index