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

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

by Pascal Dennis, John Shook, John Shook
     
 

2006 SHINGO PRIZE for EXCELLENCE in MANUFACTURING RESEARCH

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

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Overview

2006 SHINGO PRIZE for EXCELLENCE in MANUFACTURING RESEARCH

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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Product Details

ISBN-13:
9781563272622
Publisher:
Taylor & Francis
Publication date:
08/01/2002
Edition description:
Older Edition
Pages:
224
Product dimensions:
7.00(w) x 9.90(h) x 0.50(d)

Table of Contents

Forewardix
Prefacexi
1.The Birth of Lean Production1
Craft Production1
The Mass Production System2
The Growing Dysfunction5
The Birth of Lean Production6
The Historic Bargain7
A Virtue of Necessity9
Completing the Lean Revolution at Toyota10
Summary10
2.The Lean Production System13
Why Lean Production?13
Systems and Systems Thinking15
Basic Image of Lean Production17
Customer Focus19
Muda20
Summary25
3.Stability27
Standards in the Lean System27
The 5S System29
Total Productive Maintenance36
Summary43
4.Standardized Work47
Methods Engineering versus Lean Thinking47
What Do We Have to Manage?48
Why Standardized Work?49
The Elements of Standardized Work51
Charts Used to Define Standardized Work53
Manpower Reduction57
Overall Efficiency versus Individual Efficiency58
Standardized Work and Kaizen60
Common Layouts61
Summary61
5.Just-In-Time65
Why JIT?65
Basic Principles of JIT66
The JIT System69
Kanban70
The Six Kanban Rules74
Expanded Role of Conveyance76
Production Leveling78
Three Types of Pull Systems80
Value Stream Mapping82
Summary85
6.Jidoka89
Development of the Jidoka Concept89
Why Jidoka?90
Poka-yoke91
Inspection Systems and Zone Control92
Using Poka-yokes93
Implementing Jidoka97
Summary99
7.Involvement--The Wind That Fills the Sail101
Why Involvement?101
The Terrible Waste of Humanity102
Activities Supporting Involvement103
Kaizen Circle Activity103
Practical Kaizen Training107
Suggestion Programs108
Summary112
8.Hoshin Planning115
What Is Planning?115
Why Plan?117
Problems with Planning117
Hoshin Planning118
Hoshin Planning System120
The Four Phases of Hoshin Planning125
Summary133
9.The Culture of Lean Production135
What Is Lean Culture?136
How Does Lean Culture Feel?143
Summary143
Appendix IGlossary145
Appendix IIBibliography149
Index153

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