Lean Production Simplified: The Nuts and Bolts of Making Assembly Operations Flow / Edition 1

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Lean Production Simplified 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:

• An comprehensive view of Toyota's 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

Lean Production Simplified 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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Editorial Reviews

Soundview Executive Book Summaries
An engineer and educator with 20 years of experience in manufacturing, Dennis offers manufacturers a plain language guide to lean production systems. Lean Production Simplified helps manufacturers grasp the system as a whole by providing a comprehensive view of Toyota's lean manufacturing system, a look into the underlying principles of lean, and an overview of the activities that support involvement, including Kaizen circles and suggestion systems. Copyright (c) 2003 Soundview Executive Book Summaries
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Product Details

  • ISBN-13: 9781563272622
  • Publisher: Taylor & Francis
  • Publication date: 8/1/2002
  • Edition description: Older Edition
  • Edition number: 1
  • Pages: 224
  • Product dimensions: 7.00 (w) x 9.90 (h) x 0.50 (d)

Table of Contents

Foreward ix
Preface xi
1. The Birth of Lean Production 1
Craft Production 1
The Mass Production System 2
The Growing Dysfunction 5
The Birth of Lean Production 6
The Historic Bargain 7
A Virtue of Necessity 9
Completing the Lean Revolution at Toyota 10
Summary 10
2. The Lean Production System 13
Why Lean Production? 13
Systems and Systems Thinking 15
Basic Image of Lean Production 17
Customer Focus 19
Muda 20
Summary 25
3. Stability 27
Standards in the Lean System 27
The 5S System 29
Total Productive Maintenance 36
Summary 43
4. Standardized Work 47
Methods Engineering versus Lean Thinking 47
What Do We Have to Manage? 48
Why Standardized Work? 49
The Elements of Standardized Work 51
Charts Used to Define Standardized Work 53
Manpower Reduction 57
Overall Efficiency versus Individual Efficiency 58
Standardized Work and Kaizen 60
Common Layouts 61
Summary 61
5. Just-In-Time 65
Why JIT? 65
Basic Principles of JIT 66
The JIT System 69
Kanban 70
The Six Kanban Rules 74
Expanded Role of Conveyance 76
Production Leveling 78
Three Types of Pull Systems 80
Value Stream Mapping 82
Summary 85
6. Jidoka 89
Development of the Jidoka Concept 89
Why Jidoka? 90
Poka-yoke 91
Inspection Systems and Zone Control 92
Using Poka-yokes 93
Implementing Jidoka 97
Summary 99
7. Involvement--The Wind That Fills the Sail 101
Why Involvement? 101
The Terrible Waste of Humanity 102
Activities Supporting Involvement 103
Kaizen Circle Activity 103
Practical Kaizen Training 107
Suggestion Programs 108
Summary 112
8. Hoshin Planning 115
What Is Planning? 115
Why Plan? 117
Problems with Planning 117
Hoshin Planning 118
Hoshin Planning System 120
The Four Phases of Hoshin Planning 125
Summary 133
9. The Culture of Lean Production 135
What Is Lean Culture? 136
How Does Lean Culture Feel? 143
Summary 143
Appendix I Glossary 145
Appendix II Bibliography 149
Index 153
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