Beyond Lean Production: Emphasizing Speed and Innovation to Beat the Competition, 1st Edition (Paperback) book cover

Beyond Lean Production

Emphasizing Speed and Innovation to Beat the Competition, 1st Edition

By Roger G. Lewandowski

Productivity Press

108 pages | 24 B/W Illus.

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Paperback: 9781482215823
pub: 2014-02-03
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pub: 2017-07-27
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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?


About the Author

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.

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUSINESS & ECONOMICS / Workplace Culture