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Lean Production Simplified

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.
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Table of Contents

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

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.

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