1st Edition
The Toyota Kaizen Continuum A Practical Guide to Implementing Lean
Introduction
Don’t Believe Everything That You Read in a Book
ABC’s of TPS
The Kaizen Continuum
Foundational Elements of the Toyota Production System
Toyota’s Recent Turmoil
A History of the Toyota Production System
Kentucky Alchemy
Keep It Simple
The Toyota Production System versus Lean Manufacturing
Standardization
Quest for the Cube
Visiting the Plant Floor
Understanding Standardized Work
Just In Time (JIT)
The Pull System
Flow Production
Takt Time
Jidoka
Continuous Improvement (Kaizen)
Developing the Tools
Why the Toyota Production System Makes Sense: Common Sense
Common Sense 101
Understanding Value
Understanding Demand
Common Sense in Action
Common Misconceptions and Misunderstandings Regarding the Toyota Production System
TPS Misconceptions and Misunderstandings
Which Way Is Best?
Toyota Production System Historical Overview
Kanban System Overview
The Toyota Way
The Customer Knows Best
Go. See. Act
Waste Management … Improving the Manufacturing Process One Kaizen at a Time
The Three M’s
Muda
Transportation
Waiting
Overstock
Overproduction
Repair
Overprocessing
Non-Value-Added Work
Muri
Mura
Classification of Muda
Transportation
Waiting
Overstock
Overproduction
Repair
Overprocessing
Non-Value-Added Work
Muda Countermeasure Methods
Waste Elimination Example
The Golden Rules of the Toyota Production System
The Golden Rules of TPS
Simplify
Standardize
Specialize
Capital Investment Guidelines
Tangible Return on Investment Period
Recycle, Redeploy, and Reuse
Simple, Safe, and Reliable
Cost Management for Profitability
Understanding the Death Spiral
Understanding the Cost Structure
Fixed and Variable Costs
Minimum Variable Costs
Break-Even Point
Managing Costs
Managing Cost Example
Execution
The Five-Step Process for Executing Improvement Initiatives
Assessment: Understanding the Business
Setting the Course
Identify the Project Leader
Completely Understand the Project Assessment
Completely Understand the Project Target
Identify the Project Resources
Determine the Roles and Responsibilities
Develop the Plan
Completely Understand the Costs
Communicate
Execution
Rapid Implementation
Stabilization
Continuous Improvement
Conclusion
Index
Biography
John Stewart is the operating partner for Monomoy Capital Partners, a New York-based private equity fund. At Monomoy, John is responsible for portfolio management. He has worked with numerous businesses of various sizes to increase their bottom line results. Prior to joining Monomoy, John worked for Toyota Motor Corporation for eighteen years. He started with Toyota on the shop floor and worked his way through each level of the organization until he found himself responsible for Toyota’s largest European manufacturing division. John was selected by Automotive News as one of the top young professionals in the automotive industry in 2007.
