How To Implement Lean Manufacturing / Edition 1

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A Practical, Hands-on Guide to Lean Manufacturing

This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made.

How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to:

  • Rigorously test and retest the state of your "leanness" with unique evaluators
  • Develop and deploy plant-wide strategies and goals
  • Improve speed and quality and dramatically reduce costs
  • Reduce variation in the manufacturing system in order to reduce inventory
  • Reduce lead times to enable improved responsiveness and flexibility
  • Synchronize production and supply to the customer
  • Create flow and establish pull-demand systems
  • Perform system-wide and specific value-stream evaluations
  • Generate a comprehensive list of highly focused Kaizen activities
  • Sustain process gains
  • Manage constraints and reduce bottlenecks
  • Implement cellular manufacturing
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Product Details

  • ISBN-13: 9780071625074
  • Publisher: McGraw-Hill Professional Publishing
  • Publication date: 8/11/2009
  • Edition number: 1
  • Pages: 336
  • Product dimensions: 7.60 (w) x 9.30 (h) x 1.10 (d)

Meet the Author

Lonnie Wilson has been teaching and implementing Lean techniques for over 39 years. His experience spans 20 years with an international oil company where he held a number of management positions. Then in 1990 he founded Quality Consultants which teaches and applies Lean techniques to not only small entrepreneurs but also Fortune 500 firms, principally in the United States, Mexico and Canada.

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Table of Contents

Chapter 1. What Is the Perspective of This Book
Chapter 2. Lean Manufacturing and the Toyota Production System
Chapter 3. Inventory and Variation
Chapter 4. Lean Manufacturing Simplified
Chapter 5. The Significance of Lead Time
Chapter 6. How to Do Lean--Cultural Change Fundamentals
Chapter 7. How to Do Lean--The Four Strategies to Becoming Lean
Chapter 8. How to Implement Lean--The Prescription for the Lean Project
Chapter 9. Planning and Goals
Chapter 10. Sustaining the Gains
Chapter 11. Cultures
Chapter 12. Constraint Management
Chapter 13. Cellular Manufacturing
Chapter 14. The Story of the Alpha Line
Chapter 15. The Story of the Bravo Line: A Tale of Reduced Lead Times and Lots of Early Gains
Chapter 16. Using the Prescription--Three Case Studies
Chapter 17. The Precursors to Lean Not Handled Well
Chapter 18. An Experiment in Variation, Dependent Events, and Inventory
Chapter 19. Assessment Tools
Chapter 20. A House of Lean
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Customer Reviews

Average Rating 5
( 7 )
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Sort by: Showing all of 7 Customer Reviews
  • Posted October 2, 2009

    Comprehensive, Insightful, and Very Practical Guide to Lean

    I took this book on a week's vacation thinking that I would breeze through yet another book on Lean. I was very mistaken. I found myself again and again needing to slow down, think, and really consider what Lonnie Wilson is saying. There's a clarity and focus to understanding lean, and from many different perspectives, that can only come from years of experience and from deep thinking.

    I'm impressed with the breadth of treatment here: TPS as a quantity control system, the bedrock assumptions of quality control and process stability, the interrelationships with 6 Sigma and TOC, the cultural underpinnings and dynamics of cultural change, the practical tools, dealing with the real world of constraints and variation, the assessment approach along with the prescriptions, the refreshing focus on early and quantifiable gains. And along the way, detailed and insightful case studies really help to illustrate. But it's deep as well as wide: from the rigor of the mathematical calculations to the subtleties of managing cultural change. I found the idea that problem creation is a key role of management (p. 161) to be remarkably insightful.

    I've been deeply immersed in lean for the past 10 years, yet this book was completely refreshing and one that I will go back to again and again. Highly recommended whether you are just starting in or have been doing lean for years.

    1 out of 1 people found this review helpful.

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  • Posted September 29, 2009

    This book is especially useful for managers and practitioners brave enough to deal honestly with their organization's current state and capabilities.

    If this book doesn't get broad exposure and use in both industry and academia, it will be a tragedy. It is simply the new authoritative work on Lean... partly because it doesn't claim to be. The author gives credit where credit is due and even challenges much of the "new" information and approaches. And yet what he introduces or reintroduces brings clarity to a dirty pool. To be sure, he does not sugarcoat any part of the process but he does break it down to its fundamental elements and marks a clear path. From philosophical to exhaustively practical, this book treats a well-worn topic with the kind of intimacy that is born from years of experience. And it is surprisingly fresh. Do not let the book's title mislead you into thinking it deals with Lean at a superficial level. I just don't think "Understanding Lean, Assessing and Planning for Lean, Organization Development for Lean Implementation and the Essentials for Implementing and Managing Effective Lean Manufacturing" would work aesthetically. This book occupies a rare space somewhere between the tool room and the executive library.

    1 out of 1 people found this review helpful.

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  • Posted September 22, 2009

    more from this reviewer

    Practical How-to Guide on Lean!

    Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING" is a guidebook to Lean Manufacturing that will take the mystery out of process for you. It is a practical HOW-TO guide that can be used by plant managers, executives, quality managers and production personnel to implement the Lean Systems within their facilities.

    This book not only addresses the strategy on how to implement Lean Manufacturing but also addresses cultural change necessary for a successful transformation. In the end you have to sustain the gain and the book tells you what is necessary.

    What makes this book standout from other Lean texts is that the book itself is written in a Lean style of writing. Lonnie uses "Points of Clarity" to highlight important concepts within the book. Additionally he uses hundreds of visual graphics and tables that draw the reader's attention. Visual clues and organization is a key concept in Lean. I don't think you can turn two or more pages without being grabbed by a new visual to help make a point in the book.

    I was impressed with the level of practical detail. Need to calculate OEE or the proper KANBAN size? Does Value Stream Mapping have you confused? The book provides the formula's necessary. It places these concepts in context to the big picture of efficiency, lead-time or cycle-time reduction. The book is filled with personal examples from Lonnie Wilson's career leading transformation efforts. Case studies are also given to drive home and follow the complete process of a successful Lean project and some that are not so successful.

    This is a book I would personally recommend to anyone getting ready to attend a Lean training workshop. Read this book first and you will be prepared for your class. As a university instructor, I like to tell my students, "The answer is in the book". I think you will find many insightful answers about Lean in Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING".

    1 out of 1 people found this review helpful.

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  • Posted September 15, 2009

    more from this reviewer

    Great new book. The title says it all: "How to implement lean manufacturing"

    The Japanese word "sensei" is usually translated into English as "teacher" but the literal translation, and possible better translation for this purpose, is "one that has gone before".

    Lonnie Wilson's practical and pragmatic new book "How To Implement Lean Manufacturing" shows why Lonnie deserves the title "sensei". Lonnie shows us the way, and the potholes, because he has gone this way before, many times.

    Mixing lean, theory of constraints, and six sigma (aka variation reduction), Lonnie shows how to move companies forward towards a better business model and greater profits. His writing style is personal and direct which makes the book easy to read in addition to causing deep thought about our own experience, leadership, and business situation. Lonnie does not lecture on about theory but shows practical applications and examples of how to use the Toyota Production System and Lean Manufacturing in our companies here and now.

    After reading this book cover-to-cover I will keep it handy for reference and to have colleages read sections and discuss. I think everyone that is engaged in implementing Lean, or considering implementing Lean, should read this book.

    1 out of 1 people found this review helpful.

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  • Posted September 1, 2009

    more from this reviewer

    Recommended to Those Wanting to Apply Lean Techniques

    An industrial contractor once told me that he really liked the fact that companies were trying to apply Lean because he got a lot of work as a fallout of poor application.

    It's amazing to me that companies will try to adopt state-of-the-art manufacturing concepts, such as Lean, without a good understanding of what they hope to accomplish or even why the concepts have become popular.

    I think part of the reason is that there is not much useful, practical advice on how to do it.

    This book goes a long way toward filling that void.

    It is loaded with practical examples and exercises to clarify the application methods and benefits. It has some suggestions on getting started that can make you money almost immediately.

    Chapters 2-5 provide a good overview (and there is a glossary for quick reference). Chapters 6-8 give a step-by-step procedure for getting started. Other chapters explain how to advance a process already in place and several chapters have excellent case examples. I especially liked chapter 18 where there is a simple experiment with dice to show the effect of variation on plant capacity.

    I very much enjoyed reading this book because it helped me understand the principles and how to apply them. I was also impressed with how much the case studies reinforced the principles and tied them to real events. I recommend it to those who wish to implement lean in their facility.

    1 out of 1 people found this review helpful.

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  • Posted July 5, 2010

    more from this reviewer

    Clear guide to lean manufacturing

    Lonnie Wilson brings decades of experience to this practical guide. He shows you how to put lean manufacturing to work in the real world without the usual windbag textbook theories and with plentiful examples. getAbstract finds that he provides solid information about what you need to do (and don't need to do) to maximize lean's benefits for your company. Wilson is clear and strikingly passionate. His manual is not difficult to understand, but it is somewhat technical. He directs his lessons - and his informed opinions - toward those who already know a good bit about manufacturing processes. He explains how Toyota uses lean within its Toyota Production System, but he also discusses how you can put lean into practice. Wilson describes how important corporate culture is to implementing lean manufacturing and notes which aspects of your organization must align with its approach. The book is full of checklists, assessments and charts to help you get to its core principles easily and grasp them quickly without ever getting lost in a fog of philosophy.

    To learn more about this book, check out the following link:

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  • Posted October 6, 2009

    Implementing Lean

    Finally we have a "how to" that makes sense and destroys some of the myths. The myth that lean benefits will take a long time is the one I find particularly silly. Just because it took Toyota 30 years doesn't mean significant benefits can't be realized in 30 days. For sure a culture changing lean project will take time but like most changes it only takes as long as it takes to change your mind.

    The important aspects of implementing a lean change are covered in enough detail to be helpful. I found the chapter on Inventory and Variation to be most helpful. Even though the author tries to limit discussion on Lean Cultural issues the chapter on it is useful.

    I've read all the books on Toyota and Lean and I've found this book to be the most useful. Highly recommended.

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