Divided into three basic sections, this unique resource provides an understandable and implementable approach to inserting Lean in a manufacturing operation, pointing out the stumbling blocks and pitfalls to avoid. Its goal is to to help American manufacturing more effectively go about the task of making Lean a viable process. The significance of the work is that, if followed, it could change the entire course of how Lean Manufacturing is implemented in the United States and help manufacturing, in general, to become more competitive on a world wide scale.
The first section addresses the typical difficulties that manufacturing operations in the United States have with the implementation of Lean Manufacturing - pointing to three basic issues which if addressed and resolved, would serve to move the process forward in a much more rapid and effective manner. The second section focuses on how to fully resolve the issues noted and details four levels of Lean Implementation and how they can be measured, in terms of progress. The third section deals with the more advanced aspects of Lean Manufacturing, including such things as how to engage administrative and supporting functions in the process (Accounting, Materials, Sales and Marketing, etc.); How and why to perform a Core Process Analysis (in order to decide which processes should be considered for outsourcing); How to incorporate "Owner-Operators" in the process; the importance of 18 month rolling implementation plan and more.
It is sure to be found useful by high level manufacturing executives and leadership at a factory level, as well as students in a Manufacturing and Industrial Engineering curriculum.
Foreword vii
Introduction xi
Chapter 1 The Basic Flaws and Misconceptions About Lean 1
Chapter 2 As A Plant's Equipment Goes, So Goes Lean 39
Chapter 3 Accepting The Need For Change 61
Chapter 4 Setting the Stage 89
Chapter 5 Examining Level One Lean In Closer Detail 117
Chapter 6 The Search for Greatness 149
References 175
Index 177
Anonymous
Posted March 30, 2009
John Davis' book Lean Manufacturing has two expectations on the front cover: First is "A Roadmap to Quick and Lasting Success" and the second is "Implementation Strategies That Work". The book lives up to both expectations.
This easy reading book gives concise and clear insights into what to expect when attempting to implement and succeed at Lean Manufacturing. The book reflects John Davis' experience as well as his achievements in successfully changing manufacturing operations. He shares these as examples of successes and failures throughout the book.
The book points out how you (and others) fit into the change process, what you need to do to make it successful, and, what success looks like. It also details some failures and how to cope with them. Of extreme importance are the "Key Reflections" sections at the end of each chapter where Davis succinctly summarizes important learning and events making it easier for the reader to use them in their daily jobs.
Throughout the book, there are excellent true life examples of obstacles you will face as well as counter arguments on why lean won't work. These will help the reader gain insights into the challenges that lie ahead in changing a factory and how to deal with them.
Lest you think this book is for manufacturing types only, Davis clearly and thoroughly cover the role of equipment and maintenance management as critical success factors. He dwells on Total Productive Maintenance (TPM), Single Minute Exchange of Dies (SMED) and other concepts that must be addressed if you want to change from "push" manufacturing to "pull" manufacturing. Davis covers the roles and levels of all players, from the factory floor worker, to the maintenance department, and on to senior plant managers. Everyone participates in making the process a success.
I recommend this book as a "must" read for everyone working in a plant that either is implanting or have implemented Lean Manufacturing.
Overview
Divided into three basic sections, this unique resource provides an understandable and implementable approach to inserting Lean in a manufacturing operation, pointing out the stumbling blocks and pitfalls to avoid. Its goal is to to help American manufacturing more effectively go about the task of making Lean a viable process. The significance of the work is that, if followed, it could change the entire course of how Lean Manufacturing is implemented in the United States and help manufacturing, in general, to ...