Register your product to gain access to bonus material or receive a coupon.
FT Guide to Lean: How to streamline your organisation, engage employees and create a competitive edge
- By Andy Brophy
- Published Sep 4, 2012 by FT Press.
eBook (Watermarked)
- Sorry, this book is no longer in print.
- Includes EPUB and PDF
- About eBook Formats
This eBook includes the following formats, accessible from your Account page after purchase:
EPUB
The open industry format known for its reflowable content and usability on supported mobile devices.
PDF
The popular standard, used most often with the free Acrobat® Reader® software.
This eBook requires no passwords or activation to read. We customize your eBook by discreetly watermarking it with your name, making it uniquely yours.
Description
- Copyright 2012
- Edition: 1st
- eBook (Watermarked)
- ISBN-10: 0-13-383606-1
- ISBN-13: 978-0-13-383606-6
Learn how to make your company more efficient, increase customer value with less work and make better use of your organisation’s resources by implementing a Lean management strategy.
The Financial Times Guide to Lean is a guide to the tools that are used to implement Lean, showing you how to apply Lean practices fully into your organisation or company.
This book offers a comprehensive and objective look at lean strategy and how it can be tailored for different companies.
Sample Content
Table of Contents
Table of Contents
Acknowledgements
Introduction
Part I: Getting started: Lean orientation and diagnostic phase
Chapter 1 Lean management
What is Lean?
Why Lean?
Brief history of Lean
Lean today
True North Lean
The five principles
The Lean operating system
First Pillar: Continuous improvement
Second Pillar: Respect for People
Hidden waste is robbing our profits
Muda
Muri
Mura
Chapter 2 Hoshin Kanri strategy deployment
Introduction
The Hoshin process
1. Reflection on the previous year’s performance
1.2 Review of the organisations vision, mission, and values
1.3 Objectives for the forthcoming year
1.4 Alignment building and action plans
1.5 X-matrix development
1.6 Monthly evaluation
1.7 Annual evaluation
Review
Chapter 3 Value stream mapping
Introduction
What flows in value stream maps?
Value stream mapping categories
Value stream mapping stages
1. Team formation
2. Draw the current state value stream map
3. Create the ideal state value stream map
4. Develop the future state value stream map
5. Develop the improvement plan
Case Study: Outpatients orthopaedic clinic
Global background
Outpatient’s clinic overview
Current state value stream map baseline discussion
Clinic ideal state value stream map discussion
Clinic future state value stream map discussion
Box score discussion
Review
Part II: Lean transformation practices
Chapter 4 Lean methods and tools (part I)
Section 1: 5S workplace organisation
Introduction
Waste (symptom) and 5S countermeasure
How to apply 5S workplace organisation
Sort
Set-in-Order
Shine
Standardise
Sustain
5S review
Section 2: Visual management
Why use visual management
Levels of visual management
Visual management centre (VMC)
Operational tracking at the gemba
Visual management review
Chapter 5 Lean methods and tools (part II)
Section 1: A3 problem solving
Introduction
Why A3
A3 document
1. Cause and effect diagram
2. Pareto chart
3. Process map
4. Tally sheet
5. Scatter plot
6. Run chart
7. Histogram
Types of A3
Categories of problems
A3 review
Section 2: Standard work
Introduction
Standard work and job classifications
Improving standard work
Bringing standard work to life
Job breakdown sheet
Standard work review
Chapter 6 Lean methods and tools (part III)
Section1: Idea management system
Introduction
Documenting ideas is crucial
Idea metrics
Reward and recognition
Idea process flow
Idea management system review
Section 2: Kaizen events
Introduction
Kaizen stages
Pre-event preparation
Event workshop
Confirmation phase
Kaizen review
Chapter 7 Lean methods and tools (part IV)
Section 1: Quick changeover
Introduction
Why quick changeover
SMED methodology
Quick changeover review
Section 2: Total productive maintenance
Introduction
Why TPM?
Application of TPM
TPM improvement plan
TPM review
Chapter 8 Lean methods and tools (part V)
Section 1: Kanban
Introduction
Why kanban
Types of kanban
Kanban sizing calculation example
Culture and people implications
Kanban rules
Supplier kanban in a hospital setting
Kanban in a hospital setting
Kanban review
Section 2: Poke yoke
Introduction
Mistake proofing classifications
Mistake proofing routine
Poke yoke review
Chapter 9 Lean methods and tools (part VI)
Flow practices
Introduction
River and rocks analogy
Batch size implications for flow
A word on inventory
The problem with traditional production scheduling using Materials Requirement Planning (MRP)
Preconditions for flow
Family identification
Map the value stream
Identify bottlenecks and variation
Cellular flow
Human implications for flow
Flow practices review
Part III: Leading the Lean transformation
Chapter 10 Developing the Lean culture
Introduction
Cathedral model
Model foundation
Accountability process
Set expectations
Recognition
True coaching and delegation
Double diamond coaching model
Constructive feedback
Escalation
Quantity and quality
Review
Acknowledgement
Chapter 11 The technical side of sustaining Lean
Introduction
Systems thinking
Hoshin Kanri strategy deployment
Leadership
Sustaining Lean through problem solving
Lean daily management system
Training within industry (TWI)
Metrics
Review
Chapter 12 The people side of sustaining Lean
Introduction
Leadership
Engaging people in Lean
Oh, if only we had the luxury of time for improvement work!
Communication
Middle management
A propensity for risk taking
A rising tide should lift all boats
Review
Chapter 13 Putting it all together: The Lean Roadmap to Transformation
Introduction
Generic roadmap
1. Understand value through the eyes of your customers
2. Articulate the business case for transformation
3. Lean assessment
4. Value stream mapping
5. Build leadership commitment and set expectations
6. Hoshin Kanri strategy deployment
7. Management of change plan
8. Pilot Lean model area and spread plan
9. Build the Lean knowledge
10. Lean culture
11. Sustaining Lean
12. Hansei
Review
References and further reading
Glossary
Appendix
Index