3rd Edition

Lean Production Simplified A Plain-Language Guide to the World's Most Powerful Production System

By Pascal Dennis Copyright 2015
    249 Pages 3 Color & 66 B/W Illustrations
    by Productivity Press

    250 Pages
    by Productivity Press

    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.

    Watch Shingo Prize-winning author Pascal Dennis discuss Lean Production Simplified, Third Edition https://youtu.be/YD030vOb8KM

    The Birth of Lean
    Craft Production
    Mass Production
    Ford System
    Other Developments
    Growing Dysfunction
    Worker Alienation

    Birth of Lean Production
    Historic Bargain
    A Novel Concept
    A Virtue of Necessity

    Completing the Lean Revolution at Toyota
    Study Questions

    Lean Production System
    Why Lean Production?
    New Economics
    Systems and Systems Thinking
    The "Thinking Way"

    Basic Image of Lean Production
    Customer Focus
    A Word of Caution

    Study Questions

    Lean System Standards
    Visual Management
    5S System
    S2—Set in Order
    S3—Shine (and Inspect)
    Total Productive Maintenance
    Key Measures
    Six Big Losses

    The Machine Loss Pyramid
    Small-Group Activity

    Study Questions

    Standardized Work
    Methods Engineering versus Lean Thinking
    What Do We Have to Manage?
    Maximize Utilization of Machines or People?
    Labor Density

    Why Standardized Work?
    Prerequisites for Standardized Work
    Elements of Standardized Work
    Takt Time
    Takt Time and Cycle Time
    Work Sequence
    In-Process Stock

    Charts Used to Define Standardized Work
    Production Capacity Chart
    Manpower Reduction
    Overall Efficiency Versus Individual Efficiency
    Standardized Work and Kaizen
    Guidelines for Economy of Motion
    Guidelines for Layout and Equipment
    Guidelines for Tools and Jigs

    Common Layouts
    Connected Islands

    Connected Islands with Full-Work Control
    Study Questions

    Just-in-Time Production

    Why JIT?
    Basic Principles of JIT
    Continuous Flow

    The JIT System
    Kanban Metaphors
    Pacemaker Process
    The Store
    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
    Abnormality Control
    Two Kinds of Conveyance

    Production Leveling
    Responding to Changes in Customer Demand
    Heijunka Box

    Three Types of Pull Systems
    Type A Pull System
    Type B Pull System
    Type C Pull System

    Value Stream Mapping
    Study Questions

    Development of the Jidoka Concept
    Why Jidoka?
    How to Improve Human Reliability
    Common Errors
    Inspection Systems and Zone Control
    Judgment Inspections—Discovering Defects
    Informative Inspections—Reducing Defects
    Source Inspections—Preventing Defects
    Vertical Source Inspections
    Horizontal Source Inspections

    Using Poka-Yokes
    Two Types of Action
    Three Paths to Poka-Yoke
    Poka-Yoke Detection Methods

    Implementing Jidoka
    Annual Jidoka Strategy and Goals
    Future Directions

    Study Questions

    Why Involvement?
    Terrible Waste of Humanity
    Activities Supporting Involvement
    Goal of Involvement
    Kaizen Circle Activity
    Structure of KCA
    KCA Training
    KCA Administration
    KCA Promotion
    Role of the Manager

    Practical Kaizen Training
    Key Factors for PKT Success
    Grasping the Situation
    Problem Solving
    Role of the Supervisor

    Suggestion Programs
    Hassle-Free Process and Clear Rules
    Tangible Suggestions
    Intangible Suggestions
    Quick Decision-Making and Feedback
    Extrinsic and Intrinsic Motivation
    How to Motivate Suggestions
    Quantity First—Then Quality
    Annual Culture Hoshin

    Study Questions

    Hoshin Planning
    What Is Planning?
    Why Plan?
    Problems with Planning
    How Do We Create Flow?
    Hoshin Planning
    Focus of Hoshin Planning
    Alignment and Flexibility

    Hoshin Planning System
    Check Outcomes and Process

    Strengthen People
    The Control Department17 Concept
    A3 Thinking
    History of Report Writing
    Common Report-Writing Problems

    The Four Phases of Hoshin Planning
    Hoshin Generation
    Hoshin Deployment
    Output of Hoshin Deployment
    Hoshin Implementation
    Hoshin Evaluation
    Book of Knowledge

    Study Questions

    The Culture of Lean Production
    What Is Lean Culture?
    Grasping the Situation

    Reflection—Breakfast of Champions
    Warm Heart Principle
    Standards and Abnormality Control
    Visual Management

    Lean Production as a Path

    How Does Lean Culture Feel?
    Final Comments
    Study Questions

    Appendix A: Glossary
    Appendix B: Bibliography


    Pascal Dennis is President of Lean Pathways, an international coaching team. He is the author of four previous books on Lean management, all of which have won the prestigious Shingo Prize for outstanding research in the field of operational excellence. Pascal and his team have worked with major healthcare systems like Inova Health System, Baptist Memorial Healthcare Corporation, Health Sciences North and Salem Health, as well as Fortune 100 companies like Kimberly Clark and Lockheed Martin.

    Pascal learned the Toyota business system in leadership positions at Toyota Motor Manufacturing Canada, one of Toyota’s best plants, and has worked with leading senseis in North America and Japan.

    Pascal lives in Toronto with his wife and three children.

    For more information please visit www.leansystems.org.

    "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