1,602 pages | 712 B/W Illus.
While there are numerous Lean Certification programs, most companies have their own certification paths whereby they bestow expert status upon employees after they have participated in or led a certain number of kaizen events. Arguing that the number of kaizen events should not determine a person's expert status, The Lean Practitioner's Field Book: Proven, Practical, Profitable and Powerful Techniques for Making Lean Really Work outlines a true learning path for anyone seeking to understand essential Lean principles.
The book includes a plethora of examples drawn from the personal experiences of its many well-respected and award-winning contributors. These experts break down Lean concepts to their simplest terms to make everything as clear as possible for Lean practitioners. A refresher for some at times, the text provides thought-provoking questions with examples that will stimulate learning opportunities.
Introducing the Lean Practitioner concept, the book details the five distinct Lean Practitioner levels and includes quizzes and criteria for each level. It highlights the differences between the kaizen event approach and the Lean system level approach as well as the difference between station balancing and baton zone.
This book takes readers on a journey that begins with an overview of Lean principles and culminates with readers developing professionally through the practice of self-reliance. Providing you with the tools to implement Lean tools in your organization, the book includes discussions and examples that demonstrate how to transition from traditional accounting methods to a Lean accounting system.
The book outlines an integrated, structured approach identified by the acronym BASICS (baseline, analyze, suggest solutions, implement, check, and sustain), which is combined with a proven business strategy to help ensure a successful and sustainable transformation of your organization.
"I am shocked you show us the Lean concept (e.g. batch) from so many aspects. I think your book is suitable for MBA or part time students for university teaching. If possible, I would like to adopt your book for my students. I can understand you use so many stories to cultivate CEOs to have correct Lean ideas."
—Feng Chen, PhD, Associate Professor, Associate Head, Department of Industrial Engineering and Logistics Management, Shanghai Jiao Tong University
"I think that this book which focuses on how to accomplish Lean improvements will be really helpful. Many books in this field aim to convince managers of the benefits of Lean, but do not provide sufficient support to actually implement Lean techniques, engage workers, and create a process of continuous improvement. This book not only explains why you should empower your people, but how. The author is well known for his practical training for managers and employees in businesses all over the world. The roots of industrial engineering are re-applied to modern manufacturing and service companies, which results in many practical lessons to learn for all of us."
—Dr. Jan Riezebos, PhD, Associate Professor Operations, University of Groningen; Director, Technology Management, University of Groningen; and Member, Steering Committee, Quick Response Manufacturing Center Europe
"This team of highly regarded Lean practitioners has developed the most comprehensive Lean Field book in the market today. They lay the foundation for a structured Lean system in the opening section proceeded with an in-depth three phase approach for Lean implementation. Every leader of Lean in your company from executives to Lean implementers should consider this a must-read."
—Russ Scaffede, Co-owner, The Leadership Roadmap Institute; and past VP/GM of Toyota Motor Manufacturing, Power Train
"The Lean Practitioner’s Field Book is the most comprehensive collection of Lean materials on the market. It offers an abundance of depth on Lean philosophy, training material, and real life experiences while placing significant emphasis on the importance of leadership commitment and the need for balance between the hard (tools) and soft (culture) elements required for a successful Lean journey. This book is a must-read for all business / change leaders … regardless of where they are on their Lean journey. It will accelerate learning … and results!"
—Jack Lawless, CEO, AAC, Standard Aero
This book is one of the best Lean books which I’ve ever read. I hope many Chinese can see its Mandarin version as soon as possible. Following this guide will bring more factory efficiency and more profits for China’s enterprise as Charlie’s grandfather brought to Japan’s enterprise after World War II.
—Xinkai Li, Project Manager, PMO of State Administration of Taxation, China
"Charles Protzman’s TheLean Practitioner’s Field Book is essential reading for those starting the Lean journey and invaluable reference material for those on the journey. He and his co-authors deal with a highly technical and complex process in a practical way that can only be done by somebody that has lived, coached, and implemented Lean at every level in many organisations for many years. The book constantly questions the reader and encourages the readers to reassess themselves, their organisations, and their paradigms. The book has a conversational style which engages the reader, making an otherwise complicated subject very accessible. This book will make you want to go to work early every day to implement the expertise that Protzman and his co-authors have packed into this field book. If an organisation has the desire to become world class, then this is the roadmap to get it there."
—Fergus Woods, Head of APU Services, Dublin Aerospace Limited
"What a solid book, chocked full of practical advice and real-life examples. A book that takes us on a Lean journey, an evolution as such, teaching us why we do what we do and what the possibilities are if we can only change and control our impulses. The authors have created a roadmap to reduce waste by harnessing the energy and effort we spend each day. Each chapter unfolds understanding and intrigue, challenging the reader to do more with their new-found knowledge."
—Joseph A. Cuske, Works Manager, Amsted Rail-Columbus
"Having worked with Charlie Protzman over a long period, I know that his depth of practical experience in implementing Lean in a broad range of environments gives him extraordinary insight into the process of ‘getting Lean’ - the sum of this extensive learning is reflected in the Lean Practitioner’s Field Book. The reader will find that the stories and lessons learned which Charlie and his authors share contain critical information to develop and implement a successful Lean transformation for their organization.
Anyone reading this book, whether they are just getting started or have many Lean implementations under their belt, will discover a wealth of thought provoking material."
—Victor Chance, Vice President of Procurement, Medical Devices and Diagnostics Sector, Johnson & Johnson (Retired)
"The Lean Practitioner’s Field Book provides a great insight and key ‘know-how’ strategies for a successful Lean implementation. Definitively a ‘must-read’ to stay ahead of the Lean commercial market and get in depth into a solid trajectory to Lean transform and provide tangible bottom line results This book provides a broad hands-on and clear, assertive guidelines for sustainability to enable a positive spiral in the Lean transformation."
"Very exciting to read practical high impact success stories, with a comprehensive path, from concept to implementation and sustainability."
—Eduardo Arrioja, Lean Master, Aerospace
"An essential guide that gets results. Protzman, Whiton, and their co-authors combine in-depth knowledge, with practical know-how, in a new format to help Lean practitioner's excel in their work. Learning organizations will find this book of knowledge to be an essential guide to organizational well-being."
—Mike Galiazzo, Ph.D., President, Regional Manufacturing Institute
"There are miles between understanding Lean and being a Lean Practitioner. The Lean Practitioner’s Field Book is a must-read for those who want to close the gap."
—Rob Mionis, Operating Partner, Pamplona Capital Management, Former President and CEO, StandardAero
"Reading The Lean Practitioner’s Field Book is like having your own personal sensei. It feels like you’re exchanging experiences with a live expert."
—Rhidian Roach, Senior Director, Business Excellence, Edwards Lifesciences
"Learning one piece flow has changed our manufacturing thought process. It has dramatically reduced our production lead time and the number of defective parts produced in our plant. While learning Lean Manufacturing was challenging and at times frustrating, it was also exhilarating and very rewarding. The beauty of learning this new behavior process is that it takes an entire team effort from all involved within the organization."
—Craig B. Fankhauser, Vice President, Toledo Metal Spinning Company
"The approach of implementing Lean by Charlie Protzman in our company, completely changed our way of producing shock absorbers. We knew some of the Lean tools like SMED and 5S, but the introduction of videoing, along with product flow and work flow analyses provided a much clearer picture of all the waste and idle time. Our batch manufacturing processes were transformed to one piece flow processes, reducing our lead times literally from days to minutes, increasing output over 50 percent and freeing up many square meters of floor space. This book captures all these techniques; and if well implemented, with patience, you will find all your processes will improve dramatically."
—Ing. B. Overweg. Lean Coach, KONI BV
"There is a bit of the Lean practitioner in all of us. Hopefully, as you read this book to pursue additional knowledge, as a refresher or for reference or for academia, it can help add a bit more Lean practitioner to all of us in our never-ending journey."
—James Bond, 20 year veteran of the Toyota Management Team—Retired
Lean Overview, Lean Philosophy, History, Principles, and Change Management
Lean Philosophy and Foundations
Brief History of Lean
Waste versus Efficiency
Lean and Change Management
Phase I: Lean Tools and Implementation
Leveraging the Lean Business Delivery System for Continuous Improvement
House of Continuous Improvement
Getting Ready to Implement Lean System
BASICS Model: Baseline the Process
BASICS: Assess—PFA (TIPS)
Basics Model Assessment: Work Flow Analysis—Following the Operator (Staff)
Basics Model Assessment—SMED: Setup Reduction/Changeover Analysis
The BASICS Model: Suggest Solutions
Creating Standard Work
BASICS Model Implementation: Methodologies
Lean Material Basics
Lean Materials: Strategic
Total Productivity Maintenance
Basics Model: Check and Sustain
Lean Implementation Phase II through IVLine Balancing Approaches: Station Balancing versus Bumping and Motion Study
Heijunka: Sequencing Activities, Load Balancing
Leveraging Project Management in Lean Initiatives: Major Contributions from April Wennerberg
Lean Accounting and Accounting for Lean
Engineering and Lean
Creativity before Capital
Lean Transactional Processes
Lean and +QDIP, Huddles
Lean and Value of the Person
Creating the Learning Organization and the Theory of Lean Training
Lean Practitioner Levels
Hoshin Kanri: Strategic Planning/Policy Deployment.
Lean and Effective Meeting Techniques
Lean and Machine Shops and Job Shops
Lean Customer Relationship Management
Answers to Lean Practitioner Chapter 34—Lean Practitioner Levels
Leadership by Charles W. Protzman Sr.—CCS Manual: 8-Week Training Course to Japanese Leadership, 1948
CCS: Communications—Lessons Provided to the Japanese in 1949
The Missing Chapter by Kenneth Hopper
Answers to Lean Practitioner Tests