Lean Production Simplified A Plain-Language Guide to the World's Most Powerful Production System
Following in the tradition of its Shingo Prize-winning predecessors, Lean Production Simplified, Third Edition gives a clear overview of the structure and tools of the Lean production system. Written for the practitioner by a practitioner, it delivers a comprehensive insider's view of Lean management.
The author helps readers grasp the system as a whole, as well as the factors that animate it, by organizing the book around an image of a house of Lean production. Illustrating the eight kinds of waste, this updated edition of a bestseller:
- Describes the craft and mass production systems that preceded Lean production—including the contributions of Frederick Winslow Taylor and Henry Ford
- Explains the concepts of visual management, Five S, and Total Productive Maintenance
- Addresses just-in-time delivery of parts and products
- Examines the jidoka principle
- Covers the nervous system of Lean management, hoshin planning
- Illustrates the culture of Lean management
This edition deepens and extends the previous edition with case studies on Lean outside the factory—in settings such as health care, IT, finance, design, engineering, and beyond. The case studies are based on personal experience of actual work in organizations generating real results.
Lean Production Simplified, Third Edition covers each of the components of Lean within the context of the Lean production system. The author's straightforward common sense approach makes this book an easily accessible, on-the-floor resource for every team member.
The Birth of Lean
Birth of Lean Production
A Novel Concept
A Virtue of Necessity
Completing the Lean Revolution at Toyota
Lean Production System
Why Lean Production?
Systems and Systems Thinking
The "Thinking Way"
Basic Image of Lean Production
A Word of Caution
Lean System Standards
S2—Set in Order
S3—Shine (and Inspect)
Total Productive Maintenance
Six Big Losses
The Machine Loss Pyramid
Methods Engineering versus Lean Thinking
What Do We Have to Manage?
Maximize Utilization of Machines or People?
Why Standardized Work?
Prerequisites for Standardized Work
Elements of Standardized Work
Takt Time and Cycle Time
Charts Used to Define Standardized Work
Production Capacity Chart
Overall Efficiency Versus Individual Efficiency
Standardized Work and Kaizen
Guidelines for Economy of Motion
Guidelines for Layout and Equipment
Guidelines for Tools and Jigs
Connected Islands with Full-Work Control
Basic Principles of JIT
The JIT System
Six Kanban Rules
Expanded Role of Conveyance
How Frequently Should We Provide Production Orders?
Quick Adjustment to Demand Changes or Other Sources of Instability
Better Sense of Takt Time
Fewer Peaks and Valleys
Two Kinds of Conveyance
Responding to Changes in Customer Demand
Three Types of Pull Systems
Type A Pull System
Type B Pull System
Type C Pull System
Value Stream Mapping
Development of the Jidoka Concept
How to Improve Human Reliability
Inspection Systems and Zone Control
Judgment Inspections—Discovering Defects
Informative Inspections—Reducing Defects
Source Inspections—Preventing Defects
Vertical Source Inspections
Horizontal Source Inspections
Two Types of Action
Three Paths to Poka-Yoke
Poka-Yoke Detection Methods
Annual Jidoka Strategy and Goals
Terrible Waste of Humanity
Activities Supporting Involvement
Goal of Involvement
Kaizen Circle Activity
Structure of KCA
Role of the Manager
Practical Kaizen Training
Key Factors for PKT Success
Grasping the Situation
Role of the Supervisor
Hassle-Free Process and Clear Rules
Quick Decision-Making and Feedback
Extrinsic and Intrinsic Motivation
How to Motivate Suggestions
Quantity First—Then Quality
Annual Culture Hoshin
What Is Planning?
Problems with Planning
How Do We Create Flow?
Focus of Hoshin Planning
Alignment and Flexibility
Hoshin Planning System
Check Outcomes and Process
The Control Department17 Concept
History of Report Writing
Common Report-Writing Problems
The Four Phases of Hoshin Planning
Output of Hoshin Deployment
Book of Knowledge
The Culture of Lean Production
What Is Lean Culture?
Grasping the Situation
Reflection—Breakfast of Champions
Warm Heart Principle
Standards and Abnormality Control
Lean Production as a Path
How Does Lean Culture Feel?
Appendix A: Glossary
Appendix B: Bibliography
"There is a need for a book exactly like this, and Pascal has the experience, knowledge, and passion to write it. Pascal Dennis is one of many Westerners who, during the past 20 years, have gained firsthand experience with ‘Lean production’ or the Toyota Production System (TPS). At Toyota Motor Manufacturing Canada, one of Toyota’s early and successful efforts to transplant TPS outside the confines of Toyota City in Japan, Pascal received personalized mentoring from his trainer from Toyota City about each of the processes, systems, and philosophies explained in this book."
—John Shook, Senior Advisor, Lean Enterprise Institute; President, TWI Network, Inc., Ann Arbor, Michigan, USA
Praise for the Shingo Prize-Winning Second Edition:
"Lean Production Simplified is both enlightening and informative for all levels of ‘Lean learners.’ It is written from a very human perspective. Many prior publications focus on the ‘Lean bag of tools’ or the softer cultural aspects of Lean. Dennis' contribution is a well integrated blend of both giving the reader not only a systemic understanding of Lean, but also the clear skill development required for leadership at all levels. Wherever you are on your journey to Lean, Lean Production Simplified will provide further knowledge and insight to help achieve the next level on the eternal path to perfection."
—Anne Stevens, VP, North America Vehicle Operations, Ford Motor Company
"This book is just too important! In this age of global competition threatening to annihilate all but the very Leanest, Pascal Dennis' masterwork, Lean Production Simplified: A Plain-Language Guide to the World's Most Powerful Production System, is a must-read. Midway through my career, after working at five large North American manufacturing companies, it's absolutely crystal clear that the three which ‘died’ would have survived if only they'd known of and successfully implemented The Toyota Production System."
—Michael A. J. Davis, Executive VP, Waterville TG, Inc.
"Lean Production Simplified goes beyond being a ‘primer’ for the Toyota Production System - it is ‘Lean thinking’ at its best, revealed and explained. Pascal Dennis has drawn from his own experience at Toyota to help the reader understand the meaning behind their language of success, with the why's and how's explained clearly with illustrations that include the very forms used to collect and organize data. Be prepared to have your continuous improvement/people skills honed to a higher level. Whether you're a CEO, president, vice president, manager, supervisor, leader, engineer, HR specialist, employee, or a private owner, Lean Production Simplified is not a book you will read once. It's a book you will read once and then use as a reference book to read and re-read again and again, as its content is absorbed into your area of influence."
—Bob Schroer, Lean Change Agent, Lexington, Ohio