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
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.