Lean For Dummies [NOOK Book]

Overview

Take charge and engage your enterprise in a Lean transformation

Competitive pressures force everyone to satisfy more demanding customers while using less of everything — time, energy, space, materials, and money. Updated with the latest tools, advice, and information, this no-nonsense guide shows you how to apply the proven philosophies and techniques of Lean to eliminate waste and maximize the effectiveness ...

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Lean For Dummies

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Overview

Take charge and engage your enterprise in a Lean transformation

Competitive pressures force everyone to satisfy more demanding customers while using less of everything — time, energy, space, materials, and money. Updated with the latest tools, advice, and information, this no-nonsense guide shows you how to apply the proven philosophies and techniques of Lean to eliminate waste and maximize the effectiveness of your resources.

  • Lean 101 — get the skinny on the logic of Lean, from its principles to the language and lexicon of Lean
  • Power to the people — explore the often-overlooked "Respect for People" aspect of Lean to truly grasp the human side of change
  • Go with the flow — understand the way value is created and flowed to the customer
  • Fasten your toolbelt — find easy-to-follow explanations of the many customer, value stream, flow, pull, perfection, and management tools of Lean
  • It's a Lean, Lean world — take a tour of the many aspects of a Lean enterprise, from management and product development to production processes and the quality organization

"By emphasizing Lean principles and insisting on cultural transformation, Sayer and Williams empower the reader to create a lasting culture of continuous improvement."

— Robert Miller, Executive Director, The Shingo Prize for Operational Excellence

Open the book and find:

  • The common tools, principles, and practices of Lean
  • How to lead and manage a Lean organization
  • Step-by-step instructions for value-stream mapping
  • Five real-life case studies using Lean in different organizations
  • The best practices of Lean
  • How to apply Lean in different industries
  • Ten pitfalls to avoid
  • Resources you can turn to for additional help

Learn to:

  • "Go Lean" within your organization and create an environment that embraces change
  • Deliver maximum customer value to create a competitive advantage
  • Operate your business effectively — do more with less
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Product Details

  • ISBN-13: 9781118237724
  • Publisher: Wiley
  • Publication date: 4/11/2012
  • Series: For Dummies Series
  • Sold by: Barnes & Noble
  • Format: eBook
  • Edition number: 2
  • Pages: 408
  • Sales rank: 284,827
  • File size: 5 MB

Meet the Author

Natalie J. Sayer has more than 25 years of international experience as an implementer, facilitator, and consultant in continuous improvement methods. Bruce Williams is Vice President of Pegasystems, the world leader in business process management. He is a leading speaker and presenter on business and technology trends and is coauthor of Six Sigma Workbook For Dummies, Process Intelligence For Dummies, BPM Basics For Dummies, and the Intelligent Guide to Enterprise BPM.

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Table of Contents

Foreword xvii

Introduction 1

Part I: Lean Basics 7

Chapter 1: Defining Lean 9

Chapter 2: The Foundation and Language of Lean 27

Part II: The Lean Culture 47

Chapter 3: Lean in the Organization: Principles, Behaviors, and Change 49

Chapter 4: Power to the People 65

Chapter 5: Go Lean: Implementation Strategy, Startup, and Evolution 87

Part III: Understanding Flow and the Value Stream 113

Chapter 6: Seeing Value through the Eyes of the Customer 115

Chapter 7: You Are Here: Mapping the Current State 133

Chapter 8: Charting the Course: Using Value-Stream Maps 157

Chapter 9: Flowing in the Right Direction: Lean Projects and Kaizen 181

Part IV: The Lean Toolbox 199

Chapter 10: Customer and Value-Stream Tools 201

Chapter 11: Flow and Pull Tools 215

Chapter 12: Perfection Tools 237

Chapter 13: Management Tools 261

Part V: The Lean Enterprise 279

Chapter 14: Lean within the Enterprise 281

Chapter 15: Lean across Industries 305

Chapter 16: Real-Life Lean 321

Part VI: The Part of Tens 345

Chapter 17: Ten Best Practices of Lean 347

Chapter 18: Ten Pitfalls to Avoid 353

Chapter 19: Ten Places to Go for Help 361

Glossary 369

Index 373

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Interviews & Essays

Cheat Sheet for Lean For Dummies

From Lean For Dummies, 2nd Edition by Natalie J. Sayer, Bruce Williams

To understand how to apply Lean in any organization, you should know the basics: the principles, the definitions of value and waste, how to lead effectively, and how to define and improve the value stream. You should also be aware of how a Lean leader thinks and acts.

What is Lean?
Lean is a customer-centric methodology used to continuously improve any process through the elimination of waste in everything you do; it is based on the ideas of "Continuous Incremental Improvement" and "Respect for People."

Focus on the fundamentals

The basic principles of Lean are

• Focus on effectively delivering value to your Customer
• Respect and engage the people
• Improve the Value Stream by eliminating all types of waste
• Maintain Flow
• Pull Through the System
• Strive for Perfection

Your customer tells you what they value

You customer defines value or value-added with the following three conditions:

1. It must transform the product or service.

2. The customer must be willing to "pay" for it.

3. It must be done correctly the first time.

If you don't meet all three of these criteria, then you have non-value-added activities or waste.

What's "waste" anyway?

Waste comes in three main forms:

• Mura or waste due to variation
• Muri or waste due to overburdening or stressing the people, equipment or system
• Muda also known as the "seven forms of waste"

The following are the wastes most commonly associated with Lean:

Transportation: Is there unnecessary (non-value-added) movement of parts, materials, or information between processes?

• Waiting: Are people or parts, systems or facilities idle — waiting for a work cycle to be completed?
• Overproduction: Are you producing sooner, faster, or in greater quantities than the customer is demanding?
• Defects: Does the process result in anything that the customer would deem unacceptable?
• Inventory: Do you have any raw materials, work-in-progress (WIP), or finished goods that are not having value added to them?
• Movement: How much do you move materials, people, equipment, and goods within a processing step?
• Extra Processing: How much extra work is performed beyond the standard required by the customer?

Sometimes you will also hear "the disengagement of people" identified as a form of muda.

Behaviors of a Lean Leader
Lean leaders effectively exhibit the following behaviors every day. They know how the business serves the customer by

• Understanding what customers want, need, and value, or what will thrill them
• Knowing how the business satisfies the customer
• Improving the effectiveness of how the business satisfies the customer
• They build ability in the people through
• Guiding problem solving — root cause, right problem, right resources
• Leading from gemba; applying 3Gen
• Asking open-ended, probing questions
• They show a continuous improvement mindset by
• Continually challenging the status quo
• Knowing that there is always room for improvement
• Understanding that the customer changes — what delights today is a necessity tomorrow

They focus on process and results by
• Obtaining results
• Ensuring that how the results are achieved is the most effective utilization of all resources, in the direction of the ideal state
• Improving how the organization accomplishes results
• They demonstrate an understanding of the value stream at a macro and micro level through
• Knowing what the customer requires and how the value stream satisfies them
• Having knowledge of the overall value stream, including tributaries
• Asking questions when changes are made at the local level to ensure that the team understands how the change will impact the customer and the rest of the value stream
• They create a culture to sustain improvement by
• Identifying, modeling, and encouraging Lean behaviors
• Finding the lessons in every "failure" — blame does not foster improvement or innovation
• Respecting and improving standards — questions when the organization is deviating from the standard

Leading a Lean Organization
To create a sustaining Lean organization, you lead differently. Lean leaders lead from gemba, where the action happens. They know the only way to truly understand what is happening is to go to the place where the action occurs. Once there, they apply 3Gen or the 3 Actuals:
1. genchi — (like gemba) go to the actual place
2. genbutsu — observe the actual product, process or service
3. genjitsu — gather actual facts

Defining Waste in the Lean System
Waste comes in three main forms:
1. Mura or waste due to variation
2. Muri or waste due to overburdening or stressing the people, equipment or system.
3. Muda also known as the "seven forms of waste".

The Kaizen Project PDCA, or PDSA, Cycle of Lean
The term Kaizen is derived from two Japanese characters; kai, meaning "change" and zen meaning "continuous improvement." Eliminating waste in the value stream is the goal of Kaizen. The PDCA (or PDSA) Cycle is the Lean working structure -the system for executing Kaizen. The acronym stands for:
1. Plan.
Create a plan for change, identifying specifically what you want to change. Define the steps you need to make the change, and predict the results of the change.

2. Do.
Carry out the plan in a trial or test environment, on a small scale, under controlled conditions.

3. Check (or study).
Examine the results of your trial. Verify that you've improved the process. If you have, consider implementing it on a broader scale. If you haven't improved the process, go back and try again.

4. Act.
Implement the changes you've verified on a broader scale. Update the standard operating procedures.

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  • Anonymous

    Posted May 10, 2012

    This book is very well written. It provides the framework in an

    This book is very well written. It provides the framework in an easy to read format. The content is informative and covers the process and culture in tandem. The reader can understand the methodology and obtains executable tools. A must read if you want to simplify your life, streamline your business or learn how to keep your employees in touch with what the world's customers and consumers consider valuable.

    2 out of 2 people found this review helpful.

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    Posted October 19, 2011

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