Lean Production Simplified: A Plain Language Guide to the World's Most Powerful Production System / Edition 2

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Overview

Winner of a Shingo Research and Professional Publication Award

Lean Production Simplified, Second Edition 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:

  • A 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

This second edition has been updated with expanded information on the Lean Improvement Process; Production Physics and Little's Law - the fundamental equation for both manufacturing and service industries (cycle time = work in process/throughput); Value Stream Thinking - combining processes required to bring the product or service to the customer; Hoshin Planning — using the Planning and Execution Tree diagram and Problem Solving — including the "Five Why" method and how to use it.

Lean Production Simplified, Second Edition 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: 9781563273568
  • Publisher: Taylor & Francis
  • Publication date: 3/28/2007
  • Edition description: New Edition
  • Edition number: 2
  • Pages: 192
  • Sales rank: 86,717
  • Product dimensions: 7.00 (w) x 9.90 (h) x 0.60 (d)

Table of Contents

Chapter 1: The Birth of Lean Production

  • Craft Production
  • The Mass Production System
  • The Growing Dysfunction
  • The Birth of Lean Production
  • The Historic Bargain
  • A Virtue of Necessity
  • Completing the Lean Revolution at Toyota

  • Chapter 2: The Lean Production System
  • Why Lean Production?
  • Systems and Systems Thinking
  • Basic Image of Lean Production
  • Customer Focus
  • Muda

  • Chapter 3: Stability
  • Standards in the Lean System
  • The Five S System
  • Total Productive Maintenance

  • Chapter 4: Standardized Work
  • Methods Engineering versus Lean Thinking
  • What Do We Have to Manage?
  • Why Standardized Work?
  • The Elements of Standardized Work
  • Charts Used to Define Standardized Work
  • Manpower Reduction
  • Overall Efficiency versus Individual Efficiency
  • Standardized Work and Kaizen
  • Common Layouts

  • Chapter 5: Just-In-Time
  • Why JIT?
  • Basic Principles of JIT
  • The JIT System
  • Kanban
  • The Six Kanban Rules
  • Expanded Role of Conveyance
  • Production Leveling
  • Three Types of Pull Systems
  • Value Stream Mapping

  • Chapter 6: Jidoka
  • Development of the Jidoka Concept
  • Why Jidoka?
  • Poka-yoke
  • Inspection Systems and Zone Control
  • Using Poka-yokes
  • Implementing Jidoka

  • Chapter 7: Involvement - The Wind That Fills the Sail
  • Why Involvement?
  • The Terrible Waste of Humanity
  • Activities Supporting Involvement
  • Kaizen Circle Activity
  • Practical Kaizen Training
  • Suggestion Programs

  • Chapter 8: Hoshin Planning
  • What is Planning?
  • Why Plan?
  • Problems with Planning
  • Hoshin Planning
  • Hoshin Planning System
  • The Four Phases of Hoshin Planning

  • Chapter 9: The Culture of Lean Production
  • What is Lean Culture?
  • How Does Lean Culture Feel?

  • Glossary
    Bibliography
    Index
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