The Portal to Lean Production : Principles and Practices for Doing More with Less book cover
1st Edition

The Portal to Lean Production
Principles and Practices for Doing More with Less

Edited By

John Nicholas


Avi Soni

ISBN 9780849350313
Published June 20, 2007 by Auerbach Publications
342 Pages 113 B/W Illustrations

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USD $115.00

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Book Description

The Portal to Lean Production: Principles and Practices for Doing More with Less describes the steps, difficulties, and rewards of implementing lean production. The book moves beyond concepts to address practical matters. The authors provide enough information for you to begin implementing lean production within your organization.

This book applies a model-the Portal to Lean Production-to illustrate principles and practices. The model reappears at the start of every chapter and serves to connect the concepts of each chapter with those in other chapters, and with basic lean production principles.

This volume contains short vignettes that appear in every chapter of actual lean production implementations. Following these real-world examples, the text provides expanded coverage of topics to enable you to learn and apply concepts and principles. The authors enable you to see the context, application, and practical issues associated with lean production concepts and methods before learning details. The vignettes, based upon the work experience of co-author Avi Soni, help connect the concepts and tie them to practical examples.

Table of Contents

Portal to Lean Production
Race with a Moving Finish Line
Awakening to Lean Production
The Portal
The Organization of the Book


Toyota Production System
Quick History of TPS
TPS and the Portal to Lean Production

First Glimpse of a Manufacturing Cell
The Indiana Plant
Cellular Manufacturing
Throughput and Quality

Gaining Experience, Broadening the Concept
Trap Cell
Scheduling for Uniform Load
Cell Design

Applying the Cell Concept Plantwide
The Revelation
Linked Workcells and Subcells


Inventory Mess
Adopting Pull Production
Pull-Production Concepts
Number of Kanbans
Signal and Control: Methods and Issues

Total Productive Maintenance
Breakdown in the Trap Cell
Concepts of Maintenance Management
Preventive Maintenance
Total Productive Maintenance

Quick Changeover
A Tale of Two Plants
Setup Reduction Concepts and Techniques
SMED Procedure
Techniques for Setup Reduction
Attachments and Fasteners
Eliminate Adjustments
Setup-Reduction Projects
Component of a Larger System

Standard Work
Strange-Looking Charts
Concept of Standard Work
What Is Standard Work?
Critical Role in Kaizen

Focused Factories
Early Focused-Factory Experience
Focused-Factory Team Leaders
A Little Knowledge Can Be…
Clash of the Old and the New
Focused Factory
Microdesign Issues
Clustering Products and Operations
Focused-Factory Organization

Customer-Focused Quality
Listening to Your Customers
Customer Complaint
Statistical Variation
Road to Six Sigma
Quality Assurance in Lean Production
Problem-Solving Tools
Statistical Process Control
Nonstatistical Process Control
Quality at the Source
Quality Improvement and TPS


Employee Involvement, Workplace Organization, Kaizen
Employee Involvement and Workplace Organization
Value Stream Mapping
Main Vent Assembly Cell

Supply-Chain Partnerships
Learning from Our Suppliers
Problems with Parts
Building Bonds with a Supplier
Building Bonds in the Supply Chain
Supply-Chain Concept
The Lean Supply Chain
Partner Relationships
Little Customer, Big Supplier
This Can Be Difficult

The Lean Enterprise
Product Design
Lean Product Development
Process Engineering
Purchasing Function
Accounting and Finance
Sales and Marketing
Human Resources

Lean Culture Transformation
Organization Culture
Role of Management
Sustaining Momentum
Transformational Leadership
Closing Thoughts

APPENDIX A: Glossary

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