1st Edition

Henry Ford's Lean Vision Enduring Principles from the First Ford Motor Plant

By William A. Levinson Copyright 2002
    400 Pages
    by Productivity Press

    Praise from Industry Week, January 2003
    "...In Henry Ford's Lean Vision...Levinson shows how the father of American mass production toiled to eliminate waste, instituted just-in-time delivery of inventory, and applied many other tools now identified with lean..."

    Japanese manufacturers have made concepts like kaizen (continuous improvement), poka-yoke (error-proofing), and just-in-time famous. When the Japanese began to adopt these techniques from the Ford Motor Company during the early twentieth century, they knew exactly what they were getting: proven methods for mass-producing any product or delivering any service cheaply but well.

    Henry Ford's methods, however, went well beyond the synergistic and mutually supporting techniques that constitute what we now call lean manufacturing. They included the "soft sciences," the organizational psychology that makes every employee a partner in the drive for success.

    In Henry Ford's Lean Vision, William A. Levinson draws from Henry Ford's writings, the procedures in his factories, and historical anecdotes about the birth of lean in Japan to show that the philosophy that revolutionized Japanese manufacturing was the same philosophy that grew the Ford Motor Company into a global powerhouse -- and made the United States the wealthiest and most powerful nation on earth. Levinson reveals how Ford was ahead of other modern visionaries and discusses why the very ideas that made his company such a success were abandoned in his own country, and why they finally found acceptance in Japan.

    Henry Ford's Lean Vision is a hands-on reference that provides the reader with proven principles and methods that can be applied in any business or service enterprise. It covers all aspects of building and running a successful enterprise, including Ford's principles for human relationships and the management of physical resources.

    What to Expect from this Book
    Background Resources
    Chapter by Chapter Overview

    Chapter 1: Brave New World: Changing How the World Works
    The Bottom Line: Ford's Results Speak for Themselves
    Defining Lean Enterprise
    Ford's Basic Principles

    Chapter 2: Ford's Principles: The Foundation
    Natural Law
    Ford and Eastern Philosophy: The Japanese Connection
    Continuous Improvement: Kaizen
    Bringing Win-Win to the Workplace

    Chapter 3: Ford on Labor Relations
    Management and Labor as Partners
    No Free Lunch: A Key Concept
    Human Resource Practices
    Employee Housing and Stores

    Chapter 4: Principles for Organizational and Personal Success
    Breaking Down Organizational Barriers
    Corporate Culture at the Ford Motor Company
    How the Ford Motor Company Lost Its Culture

    Chapter 5: Perceiving Genuine Value
    A Warning to the United States
    Everything Must Add Value
    Middlemen Do Not Add Value
    Advertising as Waste
    No Free Lunch

    Chapter 6: Ford on Economics, Government, and Health Care
    Business Cycles
    The Stock Market Should Be Irrelevant to National Prosperity
    The Role of Inexpensive Energy
    The Role of Government
    Health Care

    Chapter 7: Eliminate Waste
    "Everything But the Squeal"
    ISO 14000 Is Free

    Chapter 8: Ford's Factory
    The Factory and the Worker
    Continuous Improvement: Kaizen
    Lean Manufacturing
    Just-In-Time (JIT) Manufacturing and Inventory Reduction
    Design for Manufacture and Design for Assembly
    Process Simplification and Improvement
    Packaging and Delivery
    Point-of-Use Assembly
    Occupational Safety
    Quality Control

    Chapter 9: Customer and Supplier Relationships
    Identifying Markets and Creating Demand
    Pricing Strategy
    Supply Chain Management

    Chapter 10: Frederick Winslow Taylor and Scientific Management
    Did Taylor Influence Ford?
    Scientific Management, Lean Manufacturing, and Kaizen Blitz
    Taylor and Motion Efficiency
    The Truth Behind Taylorism
    Principles for Change Management
    An Experimental Design Tragedy

    Chapter 11: The Influence of Benjamin Franklin
    Franklin on Waste
    Franklin on Initiative, Self-Reliance, and Persistence
    Franklin on Money




    William A. Levinson

    "Henry Ford's Lean Vision could have been written about the Theory of Constraints (TOC) as much as about Lean! To understand better TOC's concepts of Throughput World, satisfying all of the stakeholders, creating value, managing the supply chain and the constraint, the reader need only look into the fundamentals and principles of Henry Ford in Mr. Levinson's book. The book captures the idea that sustainable success must come from an integrated approach of leadership, methodology, culture and organizational alignment. Anyone who is trying to implement Theory of Constraints or Lean or other improvement methodologies should read and reread this book. Its historical analogies and numerous references to the more modern gurus make it an interesting and enjoyable read!"

    Dee Jacob, Partner, The Goldratt Institute 06/01/04