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

The Portal to Lean Production

Principles and Practices for Doing More with Less, 1st Edition

By John Nicholas, Avi Soni

Auerbach Publications

344 pages | 113 B/W Illus.

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pub: 2005-11-02
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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

About the Series

Resource Management

Learn more…

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Management Science
BUSINESS & ECONOMICS / Industries / Manufacturing Industries