Made-to-Order Lean: Excelling in a High-Mix, Low-Volume Environment, 1st Edition (Paperback) book cover

Made-to-Order Lean

Excelling in a High-Mix, Low-Volume Environment, 1st Edition

By Greg Lane

Productivity Press

224 pages

Purchasing Options:$ = USD
Paperback: 9781563273629
pub: 2007-08-15

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Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs.

About the author:

Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a  handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS.

He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales.

Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email:


"This book is an excellent resource for applying lean principles to the complex topic of high-mix, low-volume manufacturing, and is core reading material for those implementing a lean manufacturing system in this environment."

— Lee C. Banks, Senior Vice President And Operating Officer, Parker Hannifin Corporation, July, 2007

"Finally, here is a practical guide to simply introduce the Toyota Production System (TPS) in job shop environments…If you own, manage, or work in a job shop and will simply give a try to the ideas, tools and principles described in this book, I predict you will find great success and will refer to this book over and over for years."

From the Foreword by John Shook, The TWI Network, Ann Arbor, July 2007

Table of Contents

Introduction: Method and Overview

Chapter 1: Managing Visually

Chapter 2: Management Auditing: Standardized Work for Managers

Chapter 3: Associating a Time with All Work

Chapter 4: Utilizing Day-by-Hour and FIFO Boards

Chapter 5: Making Improvements When You're Short of Capacity

Chapter 6: Making Improvements When You Have Excess Capacity

Chapter 7: Using Value Stream Mapping in a Low-Volume Environment

Chapter 8: Becoming Aware of Your Inventory and Using Pull Systems

Chapter 9: Making Manpower Improvements

Chapter 10: Improving Machine Performance and Plant Layout

Chapter 11: Making Improvements through Office Department Kaizen

Chapter 12: Making Improvements through Office Process Kaizen

Chapter 13: Improving Your Product Costing



About the Author

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Purchasing & Buying