1st Edition

The Lean Anthology A Practical Primer in Continual Improvement

By Rebecca Goldberg, Elliott N. Weiss Copyright 2015
    248 Pages 89 B/W Illustrations
    by Productivity Press

    248 Pages
    by Productivity Press

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    The Lean Anthology: A Practical Primer in Continual Improvement presents operations management case studies that illustrate a Lean process improvement journey. Ideal for non-engineers, adult learners, and corporate or business education settings, this book can help you and your organization understand and apply Lean practices as part of a plan for saving money, generating revenues, or freeing up resources—particularly in settings not traditionally associated with Lean.

    The stories are easy to understand, simple accounts of everyday people negotiating life. The characters observe and integrate the principles of Lean into their personal and professional lives. Each Lean case study will help you understand and apply a different approach to the "relentless pursuit of the strategic elimination of waste."

    The stories are organized into a framework for implementing a Lean transformation called The Five Cs: Customer, Capability, Control, Coordination, and Context/Culture. These are the five stages of strategic operations design and improvement. The Five Cs framework is a new approach to understanding a Lean journey that you can apply in many settings. The Five Cs framework can help you become more effective in both your personal and professional lives.

    The book includes explanations with each case study, as well as brain teasers suitable for team discussion. These tools supply readers—even those without an operations management background—with an intuitive understanding of how to create value by eliminating waste.



    Defining the Customer Value Proposition
    Theron Hunter’s Coffee Shop
    The Value Proposition of the Coffee Shop
         Value Proposition 
         Order-Winning Criteria 
         Make to Order versus Make to Stock 
         Voice of the Customer 
         Competing on Capabilities 
         Operating System Strategic Design

    Managing Variability
    Lunch with Guinevere
    Managing Variability in Lunch Orders at the Walden-Aster
         Accommodating Variability in Demand
              Lead Time 

    Understanding Little’s Law
    Dylan and Amelia Have a Cuppa
    Moving Customers through a Pipeline 
         Little’s Law 
         Pipeline Management
         Cash Conversion Cycle

    Achieving Single-Piece Flow
    Belinda, Bags, and Batches
    Batch Sizes at the Grocery Store 
         Single-Piece Flow 
         The Social Contract and Perceptions of Fairness 
         Standard Work and Variability 
         SMED (Setup Time Reduction)


    Managing Constrained Resources
    Donna Johnson and the Bottlenecks
    Managing the Limited Resources of Time, Capacity, and Money 
         Theory of Constraints 

    Identifying Non–Value-Added Activities
    Todd’s Balancing Act
    Using Lean Techniques to Improve Daily Activities and Achieve a Goal 
         Value-Stream Mapping 
         Current- and Future-State Analysis 
         Identifying and Removing Waste
         Top-Line Metrics 
         Standard Work 
         Continuous Improvement and Kaizen

    Mapping the Value Stream
    Rebecca’s Morning Routine
    Using Critical Path and Value-Stream Mapping to Establish Standard Work at Home 
         Critical Path 
         Value-Stream Map (VSM) 

    Establishing Standard Work
    Erika, In through the Out Door
    Standardizing Work to Reduce Cycle Time in the Kitchen and Entryway 
         Identifying and Removing Muda

    Implementing the 5S System
    David and the Case of the Hoarded House
    Creating Time and Functionality with 5S 
         Standard Work 


    Using Process Behavior Charts
    Tracy Scott Manages His Blood Sugar
    Health Management through Process Behavior Charts 
         XmR Charts 
         Special and Assignable Causes 
         Reducing Variation 
         Continuous Improvement

    Designing Experiments
    Bob’s A-Maize-ing Popcorn
    Using Experiments to Create the Best Popcorn 
         Experimental Design 
         Six Sigma 
         Designing a Robust Process
         Accuracy versus Precision 
         Defining and Limiting Variables

    Maintaining Reliable Equipment
    Missy’s Car Maintenance
    Improving Automobile Performance through Total Productive Maintenance
         Predictive, Preventive, and Reactive Maintenance 
         Supplier Relationships


    Designing a Supply Chain
    Brian and Tonya’s Lunch Dilemma
    Managing the Supply Chain for a Home-Cooked Lunch 
         The Reorder Point System 
         Periodic Review Systems

    Determining Lot Size
    Peter Goes Shopping
    Determining the Optimal Lot Size for Household Supplies 
         Economic Order Quantity (EOQ) 
         Reorder Points 
         Quantity Discounts 
         Visual Management

    Order Quantities and Safety Stock
    Brad and Gina and Baby Make Three
    The Impact of Cost Estimates on Purchasing Decisions 
         Economic Order Quantity (EOQ)
         Setup Cost 
         Holding Cost 
         Safety Stock 
         Cycle Stock 
         Reorder Points (ROP) 
         Inventory Management Policies


    Enabling Rational Decision Making
    Zeke’s Tree
    Decision Analysis for Homework Success: Empowering Homework Completion Using Decision Trees 
         Decision Analysis 
         Decision Trees 
         The Socratic Method 
         The Change Effectiveness Equation

    Analyzing Root Causes
    Jackson and Wyatt Learn to Share
    Building Family Consensus through Root Cause Analysis
         Andon Cords 
         Root Cause Analysis 
         Employee Teamwork as Part of Continuous Process Improvement

    Putting It All Together
    Chloe Manages the Family Business
    Leading Strategic Change in a Family Setting
         Change Management
         Employee Development
         Employee Buy-In
         Designing a Robust Process



    Goldberg, Rebecca; Weiss, Elliott N.

    This is a truly creative and engaging book. Like Goldratt’s The Goal, this book teaches the principles and concepts that form the basis for effective management of operations through the medium of stories. Learning is fun and painless and yet the lessons are deep.
    Morris Cohen, Panasonic Professor of Manufacturing & Logistics, The Wharton School, University of Pennsylvania

    What a great book—so inviting, interesting, and creative. Great practical Lean insights from a non-manufacturing point of view.
    —Arthur V. Hill, Associate Dean for MBA Programs and Professor of Supply Chain and Operations, University of Minnesota

    Goldberg and Weiss take key business concepts and make them accessible for anyone committed to self-improvement. Their approach is simple and effective…and reminds me how much more I can do to apply Lean thinking both in and out of the office for real results!
    Kevin Klau, Senior Vice President, Business Units, Hach Company

    The Lean Anthology
    is full of rich nuggets of gold that can be applied to both personal and professional life. Rebecca Goldberg and Elliott Weiss combine storytelling and teaching through short vignettes that will revolutionize the reader’s thinking and lead to lasting business results bolstering your company’s competitive advantage. This pragmatic approach is certain to transform you, your team, and those around you.
    Monica Barker, Director Strategic Marketing North America, AREVA, Inc.

    Even experienced practitioners can use The Lean Anthology to see additional applications for Lean tools. This book is comprehensive, enlightening, refreshing, and fun to read—which allows the reader to easily follow the pragmatic presentation of each Lean concept and practice.
    Frederick S. Buchman, Co-Author of Balanced Scorecard Strategies for Dummies

    Must-reading for anyone with responsibility for or interest in any form of operations. Few managers understand and embrace the importance of continuous improvement. The challenge is to learn how to do it… this is the need this book fulfills.
    Wallace Stettinius, author of Principles of General Management, The Art and Science of Getting Results Across Organizational Boundaries, and How to Plan and Execute Strategy: 24 Steps to Implement Any Corporate Strategy Successfully