1st Edition

Beyond Lean Production
Emphasizing Speed and Innovation to Beat the Competition

ISBN 9781482215823
Published February 3, 2014 by Productivity Press
108 Pages 24 B/W Illustrations

USD $48.95

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Book Description

It is estimated that U.S. manufacturers are currently operating at only 65 percent effectiveness in implementing Lean production. Covering the fundamentals needed to be competitive in today’s marketplace, Beyond Lean Production: Emphasizing Speed and Innovation to Beat the Competition provides readers with the tools to help their organizations achieve 100 percent effectiveness in Lean production.

Explaining that overseas factories can't compete with U.S. factories in speed of delivery to domestic customers, the book provides the understanding required to add speed and urgency in all that you do in the office and the factory. It explains how to eliminate waste so you can meet and even exceed your customers’ expectations regarding service, quality, and cost.

The book is organized into two phases. The first phase, Holding Actions, covers the fundamentals needed to hold your position against the competition until you can implement the methods described in phase II of the book. It presents 12 little-known tools and strategic weapons that you can immediately put to use to improve on your current competitive position. Phase II, The Business Command Center, presents unique and powerful concepts that can be used with the fundamentals covered in phase I.

Explaining how to use speed as a competitive weapon, the book will help you to remove the obstacles that interfere with continuous flow manufacturing. It presents the concept of circulatory management that can put a stop to the ever-increasing layers of management with decreasing ownership.

By implementing the holding action and the business command center described in this book, you can significantly improve your odds of beating the competition at home and overseas.

Table of Contents


Phase 1 Holding Actions
Highlights of Key Items
Holding Action First
Tool 1: Continuous Flow Manufacturing
Tool 2: High-Velocity Working Capital
Tool 3: Process Utilization: Total Team Game Plan
Tool 4: Pull Systems
     Push Your Production Forecast out the Door and Pull in Customer Satisfaction
Tool 5: Root Cause Analysis
Tool 6: Single-Minute Exchange of Dies
Tool 7: Strategic Business Units 
     An Old Idea Updated Makes Sense: Saves People, Space, and Overhead 
     Important Points 
Tool 8: Zero-Based Process Mapping 
     Ten Steps to Process Mapping
Tool 9: Strategic Kanbans
Tool 10: Accelerated Return on Kaizen (ARK) 
     Necessity Is the Mother of Invention 
Tool 11: Supply Chain Management
Tool 12: Inventory Turns Control 
     A Items 
     B Items
     C Items
Tool 13: Mall Theory
Summary for Phase 1: Holding Actions

Phase 2 The Business Command Center
Introduction to the Business Command Center
     Bold Breakthrough that Will Make You Rethink Your Leadership
The Business Command Center
     What Is a Business Command Center?
     Implementing the Business Command Center
     Key Points of the Circulatory Management Chart
     Special Points
     Circulatory Management
     Business Command Center: Leadership
     How Do You Organize Control of the Command Center?
What Are the Benefits of Having a Business Command Center?
Future Possibilities
     Field Sales Organization
     Distribution Centers
Closing Thoughts
Further Information and Homework
Advanced Value Stream Mapping
Accounting: The Dictators of Corporations or Forgotten Priests? What Should Its Role Be?
U.S. Product Engineering: Is It a Misdirected Missile as It Is Now Organized?
Industrial Engineering: The Forgotten Function?


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With more than 30 years of manufacturing experience, Roger G. Lewandowski is the former President of Carrier Air Conditioning for all of Canada and former president of their largest division Residential Division with over $2 billion in annual sales.

After retiring from Carrier in 1993, Roger started World Competition Consultants and continues to troubleshoot for major Fortune 500 companies today. He has a vast imagination and a wealth of experience which has helped senior management develop profitable strategic plans and new approaches to marketing, sales, and distribution.

Mr. Lewandowski is a proven motivational speaker and is the author of three books: Successful Leaders’ Secrets, Revolutionary Managers’ Handbook, and The Business Command Center. Roger is a Graduate of General Motors Institute with a BS Degree in industrial engineering.