1st Edition
Lean Execution The Basic Implementation Guide for Maximizing Process Performance
Many books explain how to construct a value stream map, but few explain the process conditions and characteristics required to ensure a value stream map can be completed successfully. Lean Execution: The Basic Implementation Guide for Maximizing Process Performance fills this need.
Although the book explains Lean methods and tools that maximize process performance, its main focus is on providing readers with detailed guidelines, process conditions, and helpful tips for ensuring successful implementation.
Based on Clifford Fiore’s insights and experiences gained through years of firsthand application and implementation of Lean methods, the book supplies easy-to-understand explanations of proven Lean tools, methods, and concepts. For example, the concept of flow/theory of constraints is reviewed using a garden hose analogy.
The text introduces material in a manner that mirrors the natural sequence for general implementation. It provides simple calculations, worksheets, and examples to reinforce the key concepts involved with determining production rates and process variation.
In addition to explaining how to apply Lean tools correctly, the book provides the big picture perspective required to select and apply the appropriate Lean tool at the right time, while gaining helpful insight about the process under review. Sharing valuable lessons learned by trial and error, the book can help practitioners save valuable time and resources by not repeating similar mistakes.
The book concludes with a summary that outlines a blueprint for maximizing success during implementation.
Clifford Fiore has spent more than 30 years at a Fortune 500 company and is a recognized leader in applying Lean and Six Sigma methodologies. He is also a certified black belt and Lean expert. Through his work in adapting process improvement techniques in engineering, manufacturing, and the supply chain, he has emerged as an industry leader in implementing concepts towards reducing product cost, quality defects, and development cycle times.
SECTION I: LEAN BASICS
Lean Fundamentals
Lean or Six Sigma?
Lean History
Lean Definition
Flow
Customer Value
Waste Categories
Push versus Pull Systems
Value Streams and Value Stream Mapping
Defining a Value Stream
Mapping Considerations
Process Considerations for Value Stream Mapping
SECTION II: LEAN ASSESSMENT
Lean Baseline Assessment
Baseline Definition
Baseline Overview
Baseline Success Factors
Baseline Execution
Product Analysis
Product Analysis Overview
Time-Value Chart
Spaghetti Diagram
Communicating with Tools
Operator Analysis
Operator Analysis Overview
Takt Time
Line Balancing: The Problem
Bottlenecks
Garden Hose Analogy
Line Balancing: The Solution
Operator Process Variation
Ergonomics
Machine Analysis
Machine Analysis Overview
Overall Equipment Effectiveness
SECTION III: LEAN IMPROVEMENT
Five-S
5S Overview
5S Implementation
Standard Work
Defining Standard Work
Standard Work Tools
Adjusting Standard Work
Cell Design
Cell Definition
Visual Systems
Group Technology
Process Improvement Enablers
Setup Reduction
Total Productive Maintenance
Mistake-Proofing
Materials Management
Materials Management Overview
Kanbans
Little’s Law
Knowledge Management
Knowledge Management Overview
Knowledge Management System
General Guidelines for Lean Implementation
Lean Perspective
General Guidelines
Lean Principles
Appendix A: Using Six Sigma to Improve Product Quality
Appendix B: Forms and Worksheets
Appendix C: Glossary
Appendix D: Answers
References
Index
Biography
Clifford Fiore
"Lean Execution: The Basic Implementation Guide for Maximizing Process Performance provides a thorough, easily understandable, step-by-step ‘how-to guide’ with respect to implementing Lean activities in your organization that can be utilized as a training guide or as a concise refresher."
—Michael S. Holmes, President, Cadence Aerospace, ADM Operations