ISBN-10:
1439846049
ISBN-13:
9781439846049
Pub. Date:
09/19/2011
Publisher:
Taylor & Francis
The Toyota Kaizen Continuum: A Practical Guide to Implementing Lean / Edition 1

The Toyota Kaizen Continuum: A Practical Guide to Implementing Lean / Edition 1

by John Stewart

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Product Details

ISBN-13: 9781439846049
Publisher: Taylor & Francis
Publication date: 09/19/2011
Edition description: New Edition
Pages: 218
Sales rank: 972,020
Product dimensions: 6.90(w) x 9.90(h) x 0.60(d)

About the Author

John Stewart is an operating partner with the private equity firm Monomoy Capital Partners in New York. Mr. Stewart's professional experience includes 18 years with Toyota Motor Corporation in various operational and executive positions. During his time with Toyota, he worked his way from working as a Team Member on the Assembly line to managing the Vehicle Assembly Division for Toyota’s largest European operation in the United Kingdom.

Mr. Stewart was recognized within Toyota as being an expert at utilizing the Toyota Production System to effect change in various environments. He was often selected for some of the toughest assignments in Toyota, culminating in the turnaround of the operations in the United Kingdom. He spent over 88 weeks in Japan with Toyota. During this time, Mr. Stewart was trained by some of Toyota’s most talented Japanese masters on all things relating to the Toyota Production System. Mr. Stewart is a recognized leader in the automotive and manufacturing industry and is frequently sought after to serve as a Sr. Advisor to manufacturers across the globe. He was named one of the top 10 automotive executives by Automotive News in 2007.

Table of Contents

Introduction
Don’t Believe Everything That You Read in a Book
ABC’s of TPS
The Kaizen Continuum

Foundational Elements of the Toyota Production System
An Overview of the Toyota Production System
Toyota’s Recent Turmoil
A History of the Toyota Production System
Kentucky Alchemy
Keep It Simple
The Toyota Production System versus Lean Manufacturing
Standardization
Quest for the Cube
Visiting the Plant Floor
Understanding Standardized Work
Just In Time (JIT)
The Pull System
Flow Production
Takt Time
Jidoka
Continuous Improvement (Kaizen)
Developing the Tools

Why the Toyota Production System Makes Sense: Common Sense
Common Sense 101
Understanding Value
Understanding Demand
Common Sense in Action

Common Misconceptions and Misunderstandings Regarding the Toyota Production System
TPS Misconceptions and Misunderstandings
Which Way Is Best?
Toyota Production System Historical Overview
Kanban System Overview
The Toyota Way
The Customer Knows Best
Go. See. Act

Waste Management … Improving the Manufacturing Process One Kaizen at a Time
Gap Management
The Three M’s
Muda
Transportation
Waiting
Overstock
Overproduction
Repair
Overprocessing
Non-Value-Added Work
Muri
Mura
Classification of Muda
Transportation
Waiting
Overstock
Overproduction
Repair
Overprocessing
Non-Value-Added Work
Muda Countermeasure Methods
Waste Elimination Example

The Golden Rules of the Toyota Production System
Fundamentals
The Golden Rules of TPS
Simplify
Standardize
Specialize
Capital Investment Guidelines
Tangible Return on Investment Period
Recycle, Redeploy, and Reuse
Simple, Safe, and Reliable

Cost Management for Profitability
Understanding the Death Spiral
Understanding the Cost Structure
Fixed and Variable Costs
Minimum Variable Costs
Break-Even Point
Managing Costs
Managing Cost Example

Execution
Facing Reality
The Five-Step Process for Executing Improvement Initiatives
Assessment: Understanding the Business
Setting the Course
Identify the Project Leader
Completely Understand the Project Assessment
Completely Understand the Project Target
Identify the Project Resources
Determine the Roles and Responsibilities
Develop the Plan
Completely Understand the Costs
Communicate
Execution
Rapid Implementation
Stabilization
Continuous Improvement
Conclusion

Index

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