Lean Transformation: Cultural Enablers and Enterprise Alignment, 1st Edition (Hardback) book cover

Lean Transformation

Cultural Enablers and Enterprise Alignment, 1st Edition

By Suresh Patel

Productivity Press

249 pages | 119 B/W Illus.

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Hardback: 9781498743365
pub: 2016-07-15
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Description

Books in the Quality and Business Excellence series can help readers improve customer value and satisfaction by integrating the voice of the customer into design, manufacturing, supply chain, and field processes. Lean Transformation: Cultural Enablers and Enterprise Alignment is about the Lean system. It begins by describing the reasons why so many Lean implementations fail and explaining why managers need to focus their valuable time on early adopters rather than on trying to convert resistors.

This book describes the guiding principles of the Shingo process for continuous improvement layout and evaluation. It examines the principles, systems, and tools of continuous improvement and demonstrates how to deploy these proven methods in plants and distribution centers.

The book covers time-tested continuous improvement process tools and practices, including the visual workplace, mistake proofing, PDCA, 5S, Heijunka, standard work, Kaizen, and value stream mapping. It also examines Lean performance measures and introduces a comprehensive Lean tool assessment system.

Presenting seven proven techniques for altering and guiding a Lean culture, the book identifies a formal process for overcoming common roadblocks. It also illustrates the proliferation of the Lean initiative across an organization's various sites.

This book describes how proper assessment of Lean system tools can help your organization remain focused on system standardization and boost your organization’s sustainability efforts. It includes job descriptions of various roles in the improvement process, including those for Lean supervisor and Lean team leader, as well as a glossary that defines key terms.

Reviews

"The author’s account of these difficult and vast subjects is very praiseworthy and proof of his vast industrial experience of more than four decades of working with MNCs in Asia, Europe, and the Americas. This is an inspirational work that is easy to learn and apply by the lay reader. I highly recommend this book to all students, teachers, executives, and organizations who want to learn and implement global quality management systems, Lean Six Sigma systems, and business excellence strategies."

—Madan Mohanka, Chairman, Managing Director, and Founder, TEGA Industries Limited, Kolkata, India

Table of Contents

Introduction

History of Lean

Business Process

Roadblocks to Lean Transformation

Business Process View

Managing the Purpose

SIPOC Diagram

Embarking on the Lean Journey

Shingo Process

White Coat Leadership versus Improvement Leadership

Nurturing the Lean Culture

Techniques to Change to Lean Culture

Cross-Training: A Win-Win Situation

Steps to Implement Cross-Training

On-the-Job Training

Coaching and Mentoring

Team Management

Team Dynamics

Handling Problem People

Conflicts

Team Decision and Consensus Building

Suggestion Schemes

The Idea Board

Safe Working Environment

SECTION II: PRINCIPLES OF CONTINUOUS IMPROVEMENT PROCESS

Importance of Principles, Systems, and Tools in Continuous Improvement

What Is a Principle?

Principles of Continuous Improvement Process

Process Focus

Identification and Elimination of Barriers to Flow

Matching the Rate of Production to the Level of Customer Demand

Scientific Thinking

Jidoka (Automation—Combination of Automation and Mistake Proofing)

Integrate Improvement with Work

Seek Perfection

Quality Is Built in the Product or Service at the Source

Standard Work

Successive Checks

Self-Checks

Visual Management—Visual Factory

Mistake Proofing—Poka Yoke

Separate Man from Machine

Multiprocess Handling—Multimachine Handling

Cellular (Cell) Manufacturing

Stop and Fix

SECTION III: CONTINUOUS IMPROVEMENT PROCESS TOOLS AND PRACTICES

Continuous Improvement Process System

Visual Workplace

5S Standards System Complete with Implementation Guidelines

PDCA Model for 5S Implementation

Sort

Straighten

Shine

Standardize

Sustain

Lot Size Reduction and Production Leveling System (Heijunka)

Total Productive Maintenance System (TPM) and Its Implementation

Standard Work

Continuous Improvement

Kaizen

A3 Report

Corrective/Preventive Action System

Continuous Improvement Process Tools and Practices

Value Stream Mapping

Future State Mapping

Error Proofing

Continuous Flow or One-Piece Flow

Setup Reduction

Pull System

Kanban

SECTION IV: LEAN PERFORMANCE MEASURES AND PERFORMANCE ASSESSMENT

Lean Performance Measures

On-Time Delivery (OTD)

Cost of Nonconformance (CONC)

Lean Tool System Assessment

Value Stream Mapping

5S

Standardized Work

Total Productive Maintenance (TPM)

Error Proofing

Setup Reduction

Continuous Flow

Pull System

Tool Assessment Summary Radar Chart

Lean Assessment

Appendices:

Job Description of a Lean Supervisor

Job Description of a Lean Team Leader

Conclusion

Glossary of Terms

Bibliography

Index

About the Author

Suresh Patel is a former Technical Director and Operations Excellence Executive. He earned his BE degree in electrical engineering from M.S. University of Baroda, India, his master’s degree in production technology from South Bank University, London, and an MBA degree from the University of Texas at Brownsville. He is qualified as a Certified Reliability Engineer, Certified Quality Engineer, and Certified Management Systems Auditor by the American Society for Quality.

In his long career spanning more than four decades, he has developed a wide range of products/processes and has helped in establishing six manufacturing plants in India and five US plants in Mexico. Starting with India, his career path has enabled him to work in industries in the UK, Denmark, Belgium, Canada, USA, China, Mexico, and Chile. His career has been enriched through holding key positions with such multinational corporations as Gestetner, Motorola, United Lighting Technologies, Eaton Corporation, and Fiat Global.

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
BUS097000
BUSINESS & ECONOMICS / Workplace Culture
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing