Quantum Lean: Taking Lean Systems to the Next Level
This unique guide details a revolutionary approach to lean systems. Whereas traditional lean techniques suffer from less-than-inspiring results, Quantum Lean (QL) rethinks this subject and provides an overdue remedy. The key to this breakthrough is that QL approaches lean systems from an entirely different perspective than conventional methods. Instead of focusing on resource utilization, QL centers on achieving efficiency from the standpoint of a company’s product. The benefits from this simple departure are vast and wide-ranging. In terms of speed, effectiveness, and sustainability, QL offers a superior process for transforming an enterprise and gives practitioners a way to avoid the shortcomings that are commonplace in conventional lean.

In addition to being geared toward lean practitioners and consultants, the book is also useful for the C-suite, managers, supervisors, technical staff, and rank-and-file employees. It is intended for those who work in all economic sectors, including services, manufacturing, and government.

Key Features:

• Provides easy-to-understand QL analysis techniques that are much simpler than standard lean methods and offer uncomplicated rules of thumb for determining priorities and improvement targets
• Details a win/win/win scenario for customers, employees, and shareholders that focuses on a company’s product, avoids conflicting objectives, and enables every stakeholder to benefit
• Identifies and eliminates previously overlooked waste by analyzing operations from a QL standpoint
• Shows how to gain greater buy in and sustainability for lean initiatives by avoiding employee defensiveness and creating a genuine problem-solving mindset throughout an organization.
• Removes the steep learning curve often associated with conventional techniques and promotes rapid implementation from analysis to results
• WAV features an overall equipment effectiveness data collection form, a time study data collection sheet, and a standard work priority method, among other valuable documents—available from the Web Added Value Download Resource Center at www.jrosspub.com
1137154877
Quantum Lean: Taking Lean Systems to the Next Level
This unique guide details a revolutionary approach to lean systems. Whereas traditional lean techniques suffer from less-than-inspiring results, Quantum Lean (QL) rethinks this subject and provides an overdue remedy. The key to this breakthrough is that QL approaches lean systems from an entirely different perspective than conventional methods. Instead of focusing on resource utilization, QL centers on achieving efficiency from the standpoint of a company’s product. The benefits from this simple departure are vast and wide-ranging. In terms of speed, effectiveness, and sustainability, QL offers a superior process for transforming an enterprise and gives practitioners a way to avoid the shortcomings that are commonplace in conventional lean.

In addition to being geared toward lean practitioners and consultants, the book is also useful for the C-suite, managers, supervisors, technical staff, and rank-and-file employees. It is intended for those who work in all economic sectors, including services, manufacturing, and government.

Key Features:

• Provides easy-to-understand QL analysis techniques that are much simpler than standard lean methods and offer uncomplicated rules of thumb for determining priorities and improvement targets
• Details a win/win/win scenario for customers, employees, and shareholders that focuses on a company’s product, avoids conflicting objectives, and enables every stakeholder to benefit
• Identifies and eliminates previously overlooked waste by analyzing operations from a QL standpoint
• Shows how to gain greater buy in and sustainability for lean initiatives by avoiding employee defensiveness and creating a genuine problem-solving mindset throughout an organization.
• Removes the steep learning curve often associated with conventional techniques and promotes rapid implementation from analysis to results
• WAV features an overall equipment effectiveness data collection form, a time study data collection sheet, and a standard work priority method, among other valuable documents—available from the Web Added Value Download Resource Center at www.jrosspub.com
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Quantum Lean: Taking Lean Systems to the Next Level

Quantum Lean: Taking Lean Systems to the Next Level

Quantum Lean: Taking Lean Systems to the Next Level

Quantum Lean: Taking Lean Systems to the Next Level

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Overview

This unique guide details a revolutionary approach to lean systems. Whereas traditional lean techniques suffer from less-than-inspiring results, Quantum Lean (QL) rethinks this subject and provides an overdue remedy. The key to this breakthrough is that QL approaches lean systems from an entirely different perspective than conventional methods. Instead of focusing on resource utilization, QL centers on achieving efficiency from the standpoint of a company’s product. The benefits from this simple departure are vast and wide-ranging. In terms of speed, effectiveness, and sustainability, QL offers a superior process for transforming an enterprise and gives practitioners a way to avoid the shortcomings that are commonplace in conventional lean.

In addition to being geared toward lean practitioners and consultants, the book is also useful for the C-suite, managers, supervisors, technical staff, and rank-and-file employees. It is intended for those who work in all economic sectors, including services, manufacturing, and government.

Key Features:

• Provides easy-to-understand QL analysis techniques that are much simpler than standard lean methods and offer uncomplicated rules of thumb for determining priorities and improvement targets
• Details a win/win/win scenario for customers, employees, and shareholders that focuses on a company’s product, avoids conflicting objectives, and enables every stakeholder to benefit
• Identifies and eliminates previously overlooked waste by analyzing operations from a QL standpoint
• Shows how to gain greater buy in and sustainability for lean initiatives by avoiding employee defensiveness and creating a genuine problem-solving mindset throughout an organization.
• Removes the steep learning curve often associated with conventional techniques and promotes rapid implementation from analysis to results
• WAV features an overall equipment effectiveness data collection form, a time study data collection sheet, and a standard work priority method, among other valuable documents—available from the Web Added Value Download Resource Center at www.jrosspub.com

Product Details

ISBN-13: 9781604271751
Publisher: Ross, J. Publishing, Incorporated
Publication date: 09/29/2020
Pages: 328
Product dimensions: 6.00(w) x 9.00(h) x 0.70(d)

About the Author

Sean Fields, P.E., LSSBB, MSIE, has over 30 years of experience in a wide variety of industries, including oil field equipment manufacturing, food processing, and job shops. As a seasoned industry professional, he has worked in all phases of business, including the shop floor, quality, safety, and engineering. He is also a columnist for the Lubbock Avalanche Journal, a licensed professional engineer in the state of Texas, a certified Six Sigma Master Black Belt, and a certified QMS auditor.

Michael Sanders, Ph.D., LSSBB, MBA, is the co-founder of BeehiveFund, a non-profit organization dedicated to assisting industry. Michael has worked in every phase of the supply chain at a wide variety of companies, including serving as CEO and president of food, energy, distribution, and high-tech firms. Michael has a Ph.D. in Industrial Engineering and an MBA from Texas Tech University.

Table of Contents

Foreword ix

Preface xi

About the Authors xvii

WAV™ Page xxi

1 Denning Quantum Lean: Part 1 1

Sidebar-Why Do We Resist Change? 6

2 Defining Quantum Lean: Part 2 7

Time Is Money 8

Time and Waste 16

QL Foundation 17

Sidebar-Cautionary Tale 19

3 Defining Quantum Lean: Part 3 21

Clarification of Each Foundation Stone 21

4 Product Path Diagram 25

Key Points 26

Example-Fabrication 26

Example-Clinic 29

Example-Film 31

Summary 33

5 Quantum Lean Tools 35

DBR 36

5S/Workplace Organization 38

One-Piece Flow 39

Product-Based Layout 41

Kanban 43

Andon 46

Cells 48

Quality@Source 50

Standard Work 51

Work Balancing 51

Quick Changeover 51

QLM 52

Summary 53

6 Applying a Product Path Diagram 55

Guidelines 56

Example-Theater: Determining Priorities 57

Summary 60

Sidebar-PPD Benefits 60

Sidebar-Next-Level Improvement 61

7 A Final Review of Quantum Lean 63

Sidebar-Human versus Automated 67

8 Quantum Lean versus Other Approaches 69

A Lean Background 69

LEI Lean 70

QL versus LEI Lean 71

QL versus LEI Lean-Conceptual Differences 73

Sidebar-Value as Denned by the Customer? 75

QL versus LEI Lean-Practical Differences 75

Summary-QL versus LEI Lean 80

Sidebar-Duality 81

LAME 82

QL versus LAME 83

Summary 85

9 Inventory 87

QL Inventory Management 87

Objectives 88

System Parameters 91

Accuracy 101

Early Warning System 106

Summary 107

10 Shop-Floor Control/Logistics/Scheduling 109

Logistics and Lean 109

Logistics Foundations 112

Logistics Foundations-Priority 114

Logistics Foundations-Transparency 119

Sidebar-Dedicating Material to Orders 124

Logistics Foundations Recap 124

Scheduling 125

DBR Tips 125

Summary 127

11 5S-Workplace Organization 129

5S-When 130

5S-Where 130

Extent-How Much 5S Is Enough? 131

5S Specifics 132

Practical Tips 140

5S Alternatives 143

Summary 144

12 Kanban 147

Kanban Basics 147

Kanban-When 149

Kanban-What 150

Kanban-Implementation 150

Summary 156

Sidebar-We've Always Done It This Way! 156

13 Quick Changeover 159

Single Minute Exchange of Dies (SMED) 160

Setup Reduction 161

Setup Reduction-Examples 162

Setup Reduction-Tips 169

Summary 171

14 Quantum Lean Maintenance (QLM) 173

TPM Background 173

QL and TPM 174

QLM 177

Personnel 178

Planned Maintenance 179

Sidebar-Maintenance and Uptime Don't Always Go Hand in Hand 180

Overall Equipment Effectiveness (OEE) 182

OEE Data Collection 183

OPE 188

ORE 190

Summary 191

15 Visual/Audible/Tactile Workplace 193

Visual Workplace-Pitfalls 197

Visual Workplace-When 198

Visual Workplace-Application 200

Summary 203

16 Standard Work 205

Standard Methods-Task Time 205

Standard Methods-Variation Reduction 209

Analyzing Variation 211

Guidelines-Variance Reduction 215

Summary 217

17 Work Balancing 219

Work Balancing Elements 219

Defining Tasks 220

Estimating Task Times 223

Line Balancing-Allocating Work 225

Validation 226

Refinement 227

Summary 230

Sidebar-Adapting Line Balancing for Cellular Manufacturing 231

Sidebar-How Much Utilization Is Best? 234

Sidebar-Which Time Study Method? 235

18 Cellular Production 237

It's About the Product 237

Cells Are Sequential 237

19 Quality@Source 239

Quality@Source Basics 240

Quality@Source and Statistics 240

Sidebar-Tampering at General Motors 242

Statistics-Core Knowledge 242

Applying Statistics 245

Summary 247

20 Lean Implementations-Improving the Odds 249

Problem Definition 251

Planning 251

Follow-up 259

The Soft Side 261

The Power of Persuasion 261

Persuasion Principles 263

Motivation 267

Sidebar-Motivation 269

Summary 272

21 Potemkin Lean 273

Potemkin Lean in the Workplace 273

Another Way 278

Sidebar-Cadillac XLR 278

Summary 281

App A Inventory Primer 283

Inventory-Fundamental Elements 283

Sidebar-What's an Outage? 292

Summary 293

App B Glossary 295

App C Sources 301

Index 307

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