—Thomas A. Debrowski, Executive Vice President, Worldwide Operations, Mattel, Inc.
“When a firm outsources its operations to external suppliers, the firm is vulnerable to major and rare disruptions that can occur at any link in the global supply chain. Because these disruptions rarely occur, few firms take commensurable actions to identify, assess, mitigate and respond to various types of supply chain risks. By introducing frameworks and concepts along with several case studies and a review of academic literature, Sodhi and Tang treat this important subject with practical relevance and academic rigor. This book will bring practitioners and researchers to develop effective and efficient ways to manage supply chain risks.”
—Marshall L. Fisher, UPS Professor, Professor of Operations and Information Management and Co-Director of Fishman-Davidson Center for Service and Operations Management, The Wharton School, University of Pennsylvania
“This book ties observations in practice to methodologies and research. The rich case examples motivated the approaches and methodologies used to mitigate risks, and in the course of doing so, Sodhi and Tang provided insights on existing and new research opportunities. As a result, this book is highly relevant to both practitioners and academics. Also, the book is also written with management lessons on how risks can be mitigated, and how risks can be contained once disruptions have occurred. As such, it is also a book for management to gain insights and to develop management skills.”
—Hau L. Lee, Thoma Professor of Operations, Information and Technology and Director of the Stanford Global Supply Chain Management Forum, Graduate School of Business, Stanford University
“As companies have extended their supply chains globally and as the face increasing resource issues, they face a number of new risk challenges. While there are various case studies written about supply chain risks, this book gives a comprehensive treatment of the subject with clarity. The concepts and frameworks developed by Sodhi and Tang in this book would create awareness of this important and yet not well understood subject, and strategies described in this book would stimulate practitioners to develop a holistic approach for identifying, assessing, mitigating, and responding to different types of supply chain risks.”
—Nick Wildgoose, Global Supply Chain Proposition Manager, Zurich Insurance
In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors. The Toyota Way is the first book for a general audience that explains the management principles and business philosophy behind Toyota's worldwide reputation for quality and reliability.
Complete with profiles of organizations that have successfully adopted Toyota's principles, this book shows managers in every industry how to improve business processes by:Eliminating wasted time and resources Building quality into workplace systems Finding low-cost but reliable alternatives to expensive new technology Producing in small quantities Turning every employee into a qualitycontrol inspector
The Lean Six Sigma Pocket Toolbook is today's most complete and results-based reference to the tools and concepts needed to understand, implement, and leverage Lean Six Sigma. The only guide that groups tools by purpose and use, this hands-on reference provides:Analyses of nearly 100 tools and methodologies--from DMAIC and Pull Systems to Control Charts and Pareto Charts Detailed explanations of each tool to help you know how, when, and why to use it for maximum efficacy Sections for each tool explaining how to create it, how to interpret what you find, and expert tips
Lean Six Sigma is today's leading technique to maximize production efficiency and maintain control over each step in the managerial process. With The Lean Six Sigma Pocket Toolbook, you'll discover how to propel your organization to new levels of competitive success--one tool at a time.
—Jeffrey K. Liker, bestselling author of The Toyota Way
"[Toyota Kata is] one of the stepping stones that will usher in a new era of management thinking."
—The Systems Thinker
"How any organization in any industry can progress from old-fashioned management by results to a strikingly different and better way."
—James P. Womack, Chairman and Founder, Lean Enterprise Institute
"Practicing the improvement kata is perhaps the best way we've found so far for actualizing PDCA in an organization."
—John Shook, Chairman and CEO, Lean Enterprise Institute
This game-changing book puts you behind the curtain at Toyota, providing new insight into the legendary automaker's management practices and offering practical guidance for leading and developing people in a way that makes the best use of their brainpower.
Drawing on six years of research into Toyota's employee-management routines, Toyota Kata examines and elucidates, for the first time, the company's organizational routines--called kata--that power its success with continuous improvement and adaptation. The book also reaches beyond Toyota to explain issues of human behavior in organizations and provide specific answers to questions such as:How can we make improvement and adaptation part of everyday work throughout the organization? How can we develop and utilize the capability of everyone in the organization to repeatedly work toward and achieve new levels of performance? How can we give an organization the power to handle dynamic, unpredictable situations and keep satisfying customers?
Mike Rother explains how to improve our prevailing management approach through the use of two kata: Improvement Kata--a repeating routine of establishing challenging target conditions, working step-by-step through obstacles, and always learning from the problems we encounter; and Coaching Kata: a pattern of teaching the improvement kata to employees at every level to ensure it motivates their ways of thinking and acting.
With clear detail, an abundance of practical examples, and a cohesive explanation from start to finish, Toyota Kata gives executives and managers at any level actionable routines of thought and behavior that produce superior results and sustained competitive advantage.
Information Technology is supposed to enable business performance and innovation, improve service levels, manage change, and maintain quality and stability, all while steadily reducing operating costs. Yet when an enterprise begins a Lean transformation, too often the IT department is either left out or viewed as an obstacle. What is to be done? Winner of a 2011 Shingo Research and Professional Publication Award, this book shares practical tips, examples, and case studies to help you establish a culture of continuous improvement to deliver IT operational excellence and business value to your organization.
...will have a permanent place in my bookshelf.
—Gene Kim, Chief Technology Officer, Tripwire, Inc.
... provides an unprecedented look at the role that Lean IT will play in making this revolutionary shift and the critical steps for sustained success.
—Steve Castellanos, Lean Enterprise Director, Nike, Inc.
Twenty years from now the firms which dominate their industries will have fully embraced Lean strategies throughout their IT organizations.
—Scott W. Ambler, Chief Methodologist for Agile and Lean, IBM Rational
... a great survival manual for those needing nimble and adaptive systems.
—Dr. David Labby, MD, PhD, Medical Director and Director of Clinical Support and Innovation, CareOregon
... makes a major contribution in an often-ignored but much-needed area.
—John Bicheno, Program Director MS in Lean Operations, Cardiff University
... a comprehensive view into the world of Lean IT, a must read!
—Dave Wilson, Quality Management, Oregon Health & Science University
The authors also provide a more complete perspective on the concept of availability. While they discuss availability of equipment in transactional processes, they extend the concept by elaborating on availability as it applies to employees. The calculation of process lead time for work queues is taken to an advanced level – not only is the calculation of this lead time explained, but the text also covers the very real possibility of having more work in the queue than available time.
While previous books have focused on only production process VSM or transactional process VSM, this work meets the real needs of both manufacturers and service sector organizations by dealing with both types. It goes beyond explaining each scenario, to teach readers what techniques are commonly applicable to both, and also explains areas of difference so that mappers will be able to readily adapt to whatever unique situations present themselves.
The world's largest and most profitable companies—including the likes of GE, Bank of America, Honeywell, DuPont, Samsung, Starwood Hotels, Bechtel, and Motorola—have used Six Sigma to achieve breathtaking improvements in business performance, in everything from products to processes to complex systems and even in work environments. Over the past decade, over $100 billion in bottom-line performance has been achieved through corporate Six Sigma programs. Yet, despite its astounding effectiveness, few outside of the community of Six Sigma practitioners know what Six Sigma is all about.
With this book, Six Sigma is revealed to everyone. You might be in a company that's already implemented Six Sigma, or your organization may be considering it. You may be a student who wants to learn how it works, or you might be a seasoned business professional who needs to get up to speed. In any case, this updated edition of Six Sigma For Dummies is the most straightforward, non-intimidating guide on the market.New and updated material, including real-world examples What Six Sigma is all about and how it works The benefits of Six Sigma in organizations and businesses The powerful "DMAIC" problem-solving roadmap Yellow, Green and Black—how the Six Sigma "belt" system works How to select and utilize the right tools and technologies Speaking the language of Six Sigma; knowing the roles and responsibilities; and mastering the statistics skills and analytical methods
Six Sigma For Dummies will become everyone's No. 1 resource for discovering and mastering the world's most famous and powerful improvement tool. Stephen Covey is spot-on when he says, "Six Sigma For Dummies is a book to be read by everyone."
The McGraw-Hill 36-Hour Six Sigma Course provides you with the knowledge you need to understand, implement, and manage a Six Sigma program. This detailed yet accessible guide explores 10 essential Six Sigma tools for manufacturing along with other core components of a Six Sigma program.
In this authoritative volume, the world's top Theory of Constraints (TOC) experts reveal how to implement the ground-breaking management and improvement methodology developed by Dr. Eliyahu M. Goldratt. Theory of Constraints Handbook offers an in-depth examination of this revolutionary concept of bringing about global organization performance improvement by focusing on a few leverage points of the system. Clear explanations supplemented by examples and case studies define how the theory works, why it works, what issues are resolved, and what benefits accrue, and demonstrate how TOC can be applied to different industries and situations.
Theory of Constraints Handbook covers:Critical Chain Project Management for realizing major improvements in delivering projects on time, to specification, and within budget Drum-Buffer-Rope (DBR), Buffer Management, and distribution for maximizing throughput and minimizing flow time Performance measures for applying Throughput Accounting to improve organizational performance Strategy, marketing, and sales techniques designed to increase sales closing rates and Throughput Thinking Processes for simple and complex environments TOC methods to ensure that services actions support escalating demand for services while retaining financial viability Integrating the TOC Thinking Processes, the Strategy and Tactic Tree, TOC measurements, the Five Focusing Steps of TOC, and Six Sigma as a system of tools for sustainable improvement
Identify development waste Assess an organization’s current state and develop a Current State Map Apply Lean principles to create a Future State Map
"At Frito Lay, we have applied many of the concepts and tools in this book, and we are realizing a five to seven times return on our annual Lean Six Sigma investment."
—Tony Mattei, Lean Six Sigma Director, Frito Lay
"Ecolab has experienced a sustainable, competitive advantage through Lean Six Sigma. The principles in this book are helping us drive greater value for our share-holders, better service for our customers, and talent development opportunities for our associates."
—Jeffrey E. Burt, Vice President and Global Deployment Leader, Lean Six Sigma, Ecolab
"This book gives excellent insights into Lean Six Sigma and its strong impact within different industries. We used Lean Six Sigma in numerous process improvement projects, which, in turn, helped to create momentum and set up a process improvement culture. Amid a challenging economic environment, we are accelerating this initiative globally."
—Satheesh Mahadevan, Directeur des Processus, Société Générale
"Our Lean Six Sigma deployment of the concepts and tools described in this book is transforming our business—with tangible benefits for our employees, customers, suppliers, and shareholders."
—Jeffrey Herzfeld, Sr. Vice President and General Manager, Teva Pharmaceuticals USA
"We have deployed the holistic Lean Six Sigma strategy described by Mark George across our enterprise. It is providing remarkable returns for Unum."
—Bob Best, Chief Operating Officer, Unum
"The Lean Six Sigma Guide to Doing More with Less presents a comprehensive view of operations transformation, the approaches required for success, leadership's role, and the competitive advantage that results. Transformational changes are enabling us to do more with less, by investing and working smarter."
—Ted Doheny, President and COO, Joy Mining Machinery
Developed as a practical reference for metrology and calibration professionals, The Metrology Handbook provides a foundation for understanding basic metrology and calibration principles and practices, and is appropriate for those with intermediate or advanced experience seeking to increase their knowledge. This book is a collection of valuable information compiled by experts in the field to serve as a single resource for metrology and calibration professionals. The supplemental CD-ROM contains acronyms and abbreviations, a glossary of terms, tables and formulas, and common conversions.
Sponsored by ASQs Measurement Quality Division, this handbook serves as an excellent desktop reference for calibration technicians, supervisors, managers, quality inspectors, auditors, those in calibration and/or testing laboratories, consultants, and teachers. Whether youre changing disciplines in your career field, helping to becoming certified to a new or different standard, accepting more responsibilities as a supervisor or manager, training your fellow calibration practitioners, or using it to prepare for ASQs Certified Calibration Technician (CCT) exam, this handbook provides the information, guidance, and knowledge to help you achieve your goals.
The new and revised edition of this modern day classic provides the critical piece that will make any lean transformation a dynamic continuous success. It shows you how to implement a transformation that cannot fail by developing a culture that will have all your stakeholders involved in the process and invested in the outcome. It will teach you how to build success from the top down and the bottom up at the same time. If you are a leader at any level in an organization undergoing or considering a lean transformation, this is where you should start and finish ... and start again.
Praise for the First Edition of the Shingo Prize Winning International Bestseller. . .
... an excellent review of one of the most common implementation issues in a lean transformation -- the essential day to day work practices of team leaders/supervisors/value stream managers that enable the lean system.
-- George Koenigsaecker, President, Lean Investments, LLC
. . . reprinted seven times
The purpose of lean systems is to make problems glaringly obvious. If implementation does not include standard leadership and cultural support systems to constantly address problems, the point of the system is missed. Many books address lean tools and initial conversion, but if you want the system to stick, read David's book.
--Robert (Doc) Hall, Editor-In-Chief, Target, Association for Manufacturing Excellence
. . . now being translated into Russian, Thai, and Chinese...
Mann's book is an excellent start toward Lean Leadership as 'process-dependent' rather than 'person-dependent' in style.
--Ross E. Robson, Executive Director, Shingo Prize for Excellence in Manufacturing
Now empowered with five more years of accumulated knowledge and experience, David Mann’s seminal work:
Offers new insights on applications of lean management in administrative, technical, and professional environments Provides new guidance on how to begin implementing lean management in discrete manufacturing, office, and process manufacturing environments. Details specifics on how to engage executives through gemba walks* Shows the difference between measuring improvement through results and through processes Adds new case studies throughout Expands the lean management assessment based on actual use, and now offers up two separate versions (both available online) one for manufacturing and one for administrative, technical, and professional settings
*In a gemba walk, a teacher, or sensei, and student walk the production floor. The teacher asks the student to tell what he or she sees and, depending on the answer, asks more questions to stimulate the student to think differently about what is in front of him or her. This includes learning to see what is not there...Gemba walks often include assignments to act on what the student has come to see. ...
This completely revised reference provides a comprehensive look at software testing as part of the project management process, emphasizing testing and quality goals early on in development. Building on the success of previous editions, the text explains testing in a Service Orientated Architecture (SOA) environment, the building blocks of a Testing Center of Excellence (COE), and how to test in an agile development. Fully updated, the sections on test effort estimation provide greater emphasis on testing metrics. The book also examines all aspects of functional testing and looks at the relation between changing business strategies and changes to applications in development.
Includes New Chapters on Process, Application, and Organizational Metrics
All IT organizations face software testing issues, but most are unprepared to manage them. Software Testing and Continuous Quality Improvement, Third Edition is enhanced with an up-to-date listing of free software tools and a question-and-answer checklist for choosing the best tools for your organization. It equips you with everything you need to effectively address testing issues in the most beneficial way for your business.
“Create Marketplace Disruption is as thought-provoking as it is entertaining. Adam Hartung offers business managers and leaders new insights to long-term success that apply across markets and industries.”
–Steve Burke, President, Comcast Cable Communications, Philadelphia, PA
"Talking innovation is easier than practicing innovation. Adam offers an excellent approach for corporations to identify how to innovate to gain competitive advantage. A must read.”
–Praveen Gupta, Editor-in-Chief, International Journal of Innovation Science and Chairman, Accelper Consulting, Schaumburg, IL
Some companies can’t change in response to market disruptions. Those companies die. Other companies do respond...eventually. They survive, but they see their profits squeezed, their growth flattened. Then,there are the long-term winners: companies that create their own disruptions and thrive on change. In Create Marketplace Disruption, Adam Hartung shows how to become one of those rare companies, creating lasting growth and profits.
This book reveals why so many companies behave in ways that are utterly incompatible with long-term success...and why even “good to great” companies are struggling for air. You’ll discover how to reposition your organization away from the Flats and Swamps of traditional Defend and Extend Management and back into the Rapids of accelerated growth. Hartung demonstrates how to attack competitors’ Lock-ins, make their Success Formulas obsolete, and create the White Space needed to invent your own new formulas for success.
Create Marketplace Disruption shows how disrupting yourself is critical to reaping the benefits of market changes, and part of a process that executives and strategists can reproduce over and over again for improved results.
How we got into this mess—and how to get out of it
The myth of perpetuity and the dark side of success
Reinventing success: no more Defend and Extend
Creating your new Success Formulas and keeping them competitively advantaged
Why “thinking outside the box” doesn’t work
First, get outside the box. Then, think!
Maintaining ”The Phoenix Principle” for long-term success
Practicing Disruption until it comes naturally
Bridging the kata/TWI nexus, the book lays out a road map for Lean success. It devotes a chapter to each of the Seven Kata and suggests possible courses of action dependent on your organization’s strengths and constraints. Bringing together valuable information on many of the disjointed Lean practices, it explains key Lean concepts, including gemba walks, genchi gembutsu, and PDCA.
After introducing kata, it reveals the different kata inherent in the three major TWI courses and the TWI Job Safety course. It illustrates the value stream analysis relationship to the kata and the kata relationship to TWI. It also demonstrates how to use kata to solve the problems identified in your value stream analysis while simultaneously conditioning your employees’ adaptive thinking patterns.
Supplying a clear understanding of exactly where the seven kata apply in your Lean journey, the authors include helpful guidelines for coaching a kata. They also highlight mistakes they have experienced or witnessed so you can avoid the same pitfalls. As globalism continues to make management’s organizational skills a competitive differentiator, this book provides you with the tools to use the seven kata to place your organization on a discernible path towards operational excellence.
Listen to what Pat Boutier has to say about The Seven Kata.Part One — Part Two
Toyota Kaizen Methods: Six Steps to Improvement focuses on the skills and techniques practiced inside Toyota Motor Corporation during the past decades. This workbook focuses on the actual training course concepts and methods used by Toyota to develop employee skill level, a core element of Toyota’s success. It is not a book about holding Western-style five-day Kaizen events, which were in reality quite rare during the development of Toyota’s production system and are virtually nonexistent today inside Toyota. Written by two of Toyota’s most revered and experienced trainers, the book —
Traces the origins of Kaizen since the inception of Toyota Motor Corporation Articulates the basic six-step Kaizen improvement skills pattern taught inside Toyota Helps practitioners of Kaizen improve their own skill level and confidence by simplifying concepts and removing any mystery in the process Provides homework assignments and a wealth of forms for analyzing work processes
If you take the time to study the concepts detailed here, you will be reviewing the same methods and techniques that were harnessed by generations of Toyota supervisors, managers, and engineers. These techniques are not the secret ingredient of Lean manufacturing; however, mastery of these timeless techniques will improve your ability to conduct improvement in almost any setting and generate improvement results for your organization.
Achieving Lean Changeover: Putting SMED to Work is about the practical implementation of the single minute exchange of die (SMED) philosophy developed by Shigeo Shingo at Toyota. Although the book is principally about changeover of manufacturing, packaging, and assembly processes, the general concepts and examples are also applicable in lighter industries that require turnover of processes—including airlines, hospitals, operating rooms, and food service.
Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities.
The author addresses both the machinery issues with changeover/ SMED and the associated operational issues such as costs, waiting times, material movement, documentation, and product/component design. He also devotes a chapter to discussing, in detail, how to calculate the cost of changeover downtime, an area that remains a mystery to many.
Taking a holistic approach to changeover, the text includes a chapter devoted to organizing changeover improvements, keeping them on track, and developing and implementing a formal changeover reduction program. Presenting time-tested methods and practical examples from a variety of industries, it offers you the opportunity to reduce changeover time and cost and provide your organization with the flexibility needed to better satisfy your customers in three important dimensions: product variety, responsiveness, and price.
The book begins with a review of the principles of the Toyota Way through the 4Ps model-Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota's lean systems will be provided with the inside knowledge they need toDefine the companies purpose and develop a long-term philosophy Create value streams with connected flow, standardized work, and level production Build a culture to stop and fix problems Develop leaders who promote and support the system Find and develop exceptional people and partners Learn the meaning of true root cause problem solving Lead the change process and transform the total enterprise
The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker's extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.
For CEOs, CIOs, CFOs, and IT leaders: The green IT business case and best practices for making it happen Timely help for companies facing rising energy costs, new government rules, and growing public concern Powerful new insights from IBM’s breakthrough $1 billion green computing initiative
Chances are your enterprise IT organization has a significant carbon footprint. In an era of unpredictable energy costs, reducing energy usage throughout your data centers and IT infrastructure represents a powerful cost-cutting opportunity. Now, a top green IT expert shows business and IT leaders how to drive powerful business value by improving IT’s environmental performance.
Drawing on leading-edge experience, John Lamb helps you realistically assess the business case for green IT, set priorities, and overcome the internal and external challenges to making it work. He offers proven solutions for issues ranging from organizational obstacles to executive motivation and discusses crucial issues ranging from utility rate incentives to metrics. Along the way, you’ll discover energy-saving opportunities–from virtualization and consolidation to cloud and grid computing–and solutions that will improve business flexibility as they reduce environmental impact.
Lamb presents case studies, checklists, and more–all the practical guidance you need to drive maximum bottom-line value from your green IT initiative.
In The Power of LEO, Chowdhury outlines a simple, three-part strategy for building continuous quality improvement every business operation, which he calls LEO: Listen to your customers and employees; Enrich your company by fixing the problems you learn about and seizing future opportunities; and Optimize your company by making sure the problems remains fixed and executing resulting plans for improvement.
Subir Chowdhury is the author of 13 books including the international bestsellers The Power of Six Sigma and The Ice Cream Maker. As chairman and CEO of ASI Consulting Group (www.asiusa.com), he advises CEOs and senior leaders of Fortune 100 companies, and in private and public sectors all over the world, helping them make ‘quality’ a part of their business culture. In 2009, the U.S. Department of Homeland Security presented him with the ‘Outstanding American by Choice Award’. His works are cited frequently in the national and international media. He lives with his family in Bloomfield Hills, Michigan.
Filling this need, The SAP Materials Management Handbook provides a complete understanding of how to best configure and implement the SAP MM module across various types of projects. It uses system screenshots of real-time SAP environments to illustrate the complete flow of business transactions involved with SAP MM. Supplying detailed explanations of the steps involved, it presents case studies from actual projects that demonstrate how to convert theory into powerful SAP MM solutions. Includes tips on the customization required for procurement of materials and inventory management Covers the range of business scenarios related to SAP MM, including the subcontracting cycle and consignment cycle Provides step-by-step guidance to help you implement your own SAP MM module Illustrates the procure to pay lifecycle Depicts critical business flows with screenshots of real-time SAP environments
This much-needed reference explains how to use the SAP MM module to take care of the range of business functions related to purchasing, including purchase orders, purchase requisitions, outline contracts, and request for quotation. It also examines all SAP MM inventory management functions such as physical inventory, stock overview, stock valuation, movement types, and reservations—explaining how SAP MM can be used to define and maintain materials in your systems.
By adhering to the time-tested framework outlined in the book, your organization will be able to commit to the precepts and practices that lead to successful implementations. Supplying an innovative and fast-track, yet comprehensive, approach to ERP implementation success, the book provides practical guidance to help executive leadership do the right things along the ERP journey. Explains how to engineer a project plan, generate requirements, and obtain a results-oriented commitment Details the practical deployment framework essential for success and includes a variety of tools to position an organization for success Describes how to ensure proactive involvement by the project team, executive sponsors, stakeholders, and working-level systems champions
Highlighting the essential planning ingredients that are frequently omitted from ERP implementation start-ups, the book provides readers with the planning framework and proven foundational methods and principles to ensure smooth planning and systems deployment, product quality, and maximum ROI.
The book covers everything from software selection and integration to common snags, traps, and black holes. Best practice tool sets include proven methods such as information workmanship standard, which defines quality; conference room piloting, which assists in matching teams to objectives seamlessly; education, training, and implementation framework, which addresses preparing the operating production environment; and project monitoring and deployment, covering project and risk management.
The successful application of Lean methodologies to improve process workflows is an efficient way to simplify operations and prevent mistakes. In Lean Six Sigma for the Office, Six Sigma guru James Martin presents proven modifications that can be deployed in offices, particularly those offices involved with global operations. Making use of Kaizen and Six Sigma concepts, along with Lean manufacturing principles, this book instructs managers on how they can improve operational efficiency and increase customer satisfaction.
The author brings experience gleaned from his application of these methodologies in a myriad of industries to create a practical and hands-on reference for the office environment. Using a detailed sequence of activities, including over 140 figures and tables as well as checklists and evaluation tools, he demonstrates how to realize the rapid improvement of office operations, and how to eliminate unnecessary tasks through value stream mapping (VSM).
The book also emphasizes the importance of strategic alignment of Kaizen events and the impact of organizational culture on process improvement activities. Latter chapters in the book discuss key elements of a change model in the context of transitional improvements as they relate to the process owner and local work team. By applying the proven principles found in this book, effective and sustainable organizational change can be accomplished, efficiency can be improved, and mistakes can be eliminated.
Written by the system's creator, Amoeba Management: The Dynamic Management System for Rapid Market Response provides a comprehensive introduction to this unique and time-tested method of management control and accounting. Explaining the management philosophy and principles, it unveils fresh and pragmatic insights on how to foster a culture of leadership and responsibility in your organization. Dr. Kazuo Inamori, director and chairman emeritus of Japan Airlines, founder and chairman emeritus of Kyocera Corporation, and honorary adviser of KDDI Corporation, delves into decades of experience creating and implementing this system to supply you with invaluable operational guidance on how to monitor and manage every aspect of your company.
Facilitating the understanding required to divide your organization into small units with self-supporting accounting, this book supplies the tools to achieve a system of management by all whereby all amoeba members focus their strengths on accomplishing common goals. It provides a means for making the concept of "value-added" truly operational for every employee and describes the features and use of the Hourly Efficiency Report, the primary mechanism used to control profits. Even companies with stagnating profitability will be able to transform themselves into high-profit enterprises using the methods described in this book.
Known as the JIT bible in Japan, JIT Implementation Manual — The Complete Guide to Just-in-Time Manufacturing presents the genius of Hiroyuki Hirano, a top international consultant with vast experience throughout Asia and the West. Encyclopedic in scope, this six-volume practical reference provides unparalleled information on every aspect of JIT— the waste-eliminating, market-oriented production system. This historic, yet timeless classic is just as crucial in today’s fast-changing global marketplace as when it was first published in Japan 20 years ago.
Providing a comprehensive introduction to the just-in-time production system, Volume 1: The Just-in-Time Production System dispels outdated myths and ideas about manufacturing that are still prevalent. Supplying essential background information on the JIT approach to production management, this user-friendly resource builds a strong foundation for implementation.
Organizations have the power to increase organizational competitiveness in an era of globalization through the application of Lean Six Sigma Operational performance directly correlates with an organization’s financial, operational and resultant productivity, as well as with shareholder EVA metrics, and geographical, cultural, technological and economic isolation Value-adding activities and disciplines such as Lean Six Sigma are not exclusive to any one country or region and do not always depend upon cost considerations
A Practical Tool for Real World Application
For organizations seeking a source for improving manufacturing and service operations, this bookeffectively delivers. Divided into 5 successive sections, it begins with adaptation strategies for global competitiveness, then delves into implementations to enhance productivity while targeting customer needs and value expectations. Finally, the author explains how to establish information-sharing throughout global supply chains, along with the role of IT. A useful tool for real world application, the volume’s 20 chapters also contain more than 450 figures and roadmaps. As organizations understand the interrelationships of the supply chains, their operational systems will excel at meeting or exceeding customer expectations in this age of globalization.
The aim of this book is to show how R can be used as the software tool in the development of Six Sigma projects. The book includes a gentle introduction to Six Sigma and a variety of examples showing how to use R within real situations. It has been conceived as a self contained piece. Therefore, it is addressed not only to Six Sigma practitioners, but also to professionals trying to initiate themselves in this management methodology. The book may be used as a text book as well.
Lean Production Simplified, Second Edition is a plain language guide to the lean production system written for the practitioner by a practitioner. It delivers a comprehensive insider's view of lean manufacturing. The author helps the reader to grasp the system as a whole and the factors that animate it by organizing the book around an image of a house of lean production.
Highlights include: A comprehensive view of Toyota1s lean manufacturing system A look at the origins and underlying principles of lean Identifying the goals of lean production Practical problem solving for lean production Activities that support involvement - Kaizen circles, suggestion systems, and problem solving
This second edition has been updated with expanded information on the Lean Improvement Process; Production Physics and Little's Law - the fundamental equation for both manufacturing and service industries (cycle time = work in process/throughput); Value Stream Thinking - combining processes required to bring the product or service to the customer; Hoshin Planning -- using the Planning and Execution Tree diagram and Problem Solving -- including the "Five Why" method and how to use it.
Lean Production Simplified, Second Edition covers each of the components of lean within the context of the entire lean production system. The author's straightforward common sense approach makes this book an easily accessible on-the-floor resource for every operator.
The new edition of this Shingo Prize-winning bestseller provides critical insights and approaches to make any Lean transformation an ongoing success. It shows you how to implement a sustainable, successful transformation by developing a culture that has your stakeholders throughout the organizational chart involved and invested in the outcome. It teaches you how to successfully navigate the politics in cross-functional process improvement projects, and to engage executives in ways that are personally meaningful to them. If you are a leader at any level in an organization undergoing or considering a Lean transformation, this is where you should start and finish ... and start again.
Read the Reviews:
"This book became an instant classic in the literature of professional operations. In this third edition, David Mann updates and expands his teaching with five additional years of valuable experience and expertise derived from his very active, multi-industry consultancy. I have benefitted greatly from his writing and wholeheartedly recommend this book to be top-of-the desk of any serious Lean practitioner or performance transformation leader."
— Raymond C. Floyd, two-time Shingo Prize Winner, President and CEO, Plasco Energy Group
"David Mann builds substantially on his seminal work on the Lean management system. The book is full of new insight and polishes the most important ideas about Lean management. The new chapter on engaging executive leadership alone is worth the price of the book."
— Peter Ward, Richard M. Ross Professor and Chair, Department of Management Science, Fisher College of Business, The Ohio State University
"This book has long been my ‘go-to’ guide on Lean management practices that help create a culture of continuous improvement and excellence. I have recommended the book to countless healthcare leaders who rave about how helpful it is in translating Lean principles into daily management behaviors. The healthcare examples make it even more relevant as a must read for any hospital leader who aims to move beyond Lean tools.."
—Mark Graban, author of Lean Hospitals, co-author of Healthcare Kaizen and The Executive Guide to Healthcare Kaizen
"As more companies outside the manufacturing sector pursue Lean transformations, Creating a Lean Culture is as critical a resource as ever. Breaking down silos and navigating tricky internecine politics remain a momentous challenge, and Mann’s case-based insights are an invaluable tool."
— Peg Pennington, Executive Director, Center for Operational Excellence, Fisher College of Business, The Ohio State University
"David has once again taken the topics that trip us up and put structure and guidance around them. His new work on executive involvement is worth the price of the book all by itself. Many of us have struggled with this topic and David provides a path to success."
— Elizabeth M. King, Vice President Organizational Effectiveness, ESCO Corporation
New in the Third Edition:
Contains new chapter on engaging executives in Lean initiatives Includes 21 new case studies Presents new examples from the healthcare and process industries Includes additional gemba worksheets for learning and teaching Lean Provides expanded coverage of Lean applications in complex cross functional value stream process improvement projectsWatch David Mann discuss how the latest edition of Creating a Lean Culture can help you and your organization succeed. http://www.youtube.com/watch?v=zX7jrtV3cBA&feature=youtu.be
Tapping into four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve vertical and horizontal alignment across your organization. He details a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function. Emphasizing the importance of using Lean and Six Sigma tools to improve your business, the book:
Integrates strategy and leadership development Paves a path for culture change–Operator-Led Process Control (OLPC)—that prepares hourly employees to take control of their processes and prepares management to enable them to do it Details an audit process for tracking progress and ensuring sustainability Includes a CD with color versions of the images in the book as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can all be easily customized for the reader’s use
This resource-rich book will allow you to spell out leadership expectations and provide your employees and associates with a clear understanding of their individual roles. Helping you keep everyone in your organization focused during the quest towards sustainable manufacturing excellence, the accompanying CD supplies the tools you and your team will need to pursue it with passion, confidence, and urgency.
Listen to what Larry Fast has to say about his new book, The 12 Principles of Manufacturing Excellence.
Part One — Part Two
Notably flexible and brief, the A3 report has proven to be a key tool In Toyota’s successful move toward organizational efficiency, effectiveness, and improvement, especially within its engineering and R&D organizations. The power of the A3 report, however, derives not from the report itself, but rather from the development of the culture and mindset required for the implementation of the A3 system.
In Understanding A3 Thinking, the authors first show that the A3 report is an effective tool when it is implemented in conjunction with a PDCA-based management philosophy. Toyota views A3 Reports as just one piece in their PDCA management approach. Second, the authors show that the process leading to the development and management of A3 reports is at least as important as the reports themselves, because of the deep learning and professional development that occurs in the process. And finally, the authors provide a number of examples as well as some very practical advice on how to write and review A3 reports.
Martin Christopher, Professor of Marketing & Logistics, Cranfield School of Management
Supply chains are at the heart of competitive advantage in business today. If supply chains are managed successfully, companies will be able to deliver their products and services to customers in a smart, cost-effective way.
The key to successful supply chain management is recognising that it’s people who really drive the living supply chains that are at the heart of businesses. Supply chains are powered by the energy and expertise of employees and suppliers and by the changing wants and needs of customers. John Gattorna calls this principle of matching changing customer needs and desires with different supply chain strategies dynamic alignment.
To secure space in a new market, to grow or keep existing markets companies have to get their products out there faster. They need to be the first with new products and services and the first to match them with particular customer groups. The dynamic alignment model gives a structured way of linking customer expectations to the operational side of business while maintaining the flexibility to systematically modify fulfilment processes as customers inevitably change their buying preferences.
Their hands-on manual provides the tools and templates that can turn your company’s employees into a skilled and invested workforce capable of realizing unprecedented profits.
If you want to get from interesting displays to true standardized work, read this book.
— Jeffrey K. Liker, author, The Toyota Way
... uses cases to explain how to create no-nonsense culture change by teaching people how to do work differently, and how to relate to each other differently in order to work more effectively.
— Robert "Doc" Hall, Editor-in Chief, Target Magazine
Graupp and Wrona bring many examples of companies that [improved] competitiveness by improving their capacity to fully engage their workforce ... .
—Steven Spear, Sr. Lecturer, MIT Sloan School of Management
Value Stream Mapping is a practical, how-to guide that helps decision-makers improve value stream efficiency in virtually any setting, including construction, energy, financial service, government, healthcare, R&D, retail, and technology. It gives you the tools to address a wider range of important VSM issues than any other such book, including the psychology of change, leadership, creating teams, building consensus, and charter development.
Karen Martin is principal consultant for Karen Martin & Associates, LLC, instructor for the University of California, San Diego's Lean Enterprise program, and industry advisor to the University of San Diego's Industrial and Systems Engineering program.
Mike Osterling provides support and leadership to manufacturing and non-manufacturing organizations on their Lean Transformation Journey. In a continuous improvement leadership role for six years, Mike played a key role in Square D Company's lean transformation in the 1990s.
Written by two experts on the subject, along with a former Toyota senior executive, this book details the most celebrated supply chain operation in the world to help you form an integrated, synchronized system that will be the envy of your industry.
You will find key insight into the logic behind every point of Toyota’s supply chain, along with both the tactics and strategies you can use to build an outstanding system of your own. Toyota Supply Chain Management explains how to achieve balance and efficiency by focusing on:Variety: Determine your variety of offerings based on operational efficiency and market demand Velocity: Maintain a steady flow through all processes of the supply chain Variability: Manage inconsistencies carefully to reduce cost and improve quality Visibility: Ensure the transparency of all processes to enable continuous learning and improvement
The authors provide valuable insider tips and offer hands-on guidance for improvingproduction and operations in a variety of industries, including health care, insurance, banking, credit processing, and retailing.
With careful attention paid to every aspect of the subject—from principles and theories to operations and best practices—Toyota Supply Chain Management is the most comprehensive, insightful guide to forging a world-class supply chain system.
Includes success stories from IBM, AT&T, Dell, Cisco, Southwest Airlines, Adobe, Domo, and Acxiom
"Great brands have always started on the inside, but why are companies taking so long to leverage the great opportunities offered by internal social media? . . . The Social Employee lifts the lid on this potential and provides guidance for businesses everywhere." -- JEZ FRAMPTON, Global Chairman and CEO, Interbrand
"Get a copy of this book for your whole team and get ready for a surge in measurable social media results!" -- MARI SMITH, author, The New Relationship Marketing, and coauthor, Facebook Marketing
"Practical and insightful, The Social Employee is sure to improve your brand-building efforts." -- KEVIN LANE KELLER, E.B. Osborn Professor of Marketing, Tuck School of Business at Dartmouth College, and author, Strategic Brand Management
"This book will change how you view the workplace and modern connectivity, and inform your view of how social employees are changing how we work and create value in today's networked economy." -- DAVID ARMANO, Managing Director, Edelman Digital Chicago, and contributor to Harvard Business Review
"The Social Employee makes the compelling argument that most organizations are sadly missing a key opportunity to create a social brand, as well as to build a strong company culture." -- ANN HANDLEY, Chief Content Officer, MarketingProfs.com, and coauthor, Content Rules
When you combine Lean Production and Six Sigma, you can’t fail to deliver positive results on a continual basis. This powerful mix—called Lean Six Sigma—is what some of the world’s most successful organizations use to launch themselves ahead of the competition—and stay there.
Now, from one convenient ebook, you can access everything you need to accomplish the same goals. Lean Six Sigma—An Introduction and Toolkit provides all the background and tools you need to start your company on the path to long-term success. This two-in-one ebook contains:What Is Lean Six Sigma?
This plain-English guide explains how you can use Lean Six Sigma to identify and eliminate waste, cut costs, and grow revenue. Featuring charts, diagrams, and case studies, it walks you through all the fundamentals, explaining the "four keys" and how they apply to your own job:Delight your customers with speed and quality Improve your processes Work together for maximum gain Base decisions on data and facts The Lean Six Sigma Pocket Toolbox
The Lean Six Sigma Pocket Toolbook is today's most complete and results-based reference to the tools and concepts you need to understand, implement, and leverage Lean Six Sigma. This hands-on reference provides:Analyses of nearly 100 tools and methodologies--from DMAIC and Pull Systems to Control Charts and Pareto Charts Detailed explanations of each tool to help you know how, when, and why to use it for maximum efficacy Sections for each tool explaining how to create it, how to interpret what you find, and expert tips
"The Six Sigma Way demystifies Six Sigma with a real-world 'how-to 'guide. A good investment for any business planning to launch Six Sigma."
John Biedry, VP Quality & Compliance, Sears Home Services.
Cost reduction...productivity improvement...customer retention...these are the promises of the Six Sigma quality management system. The Six Sigma Way reveals how GE, Motorola, and numerous other companies are successfully using Six Sigma to fine-tune products and processes, improve performance, and increase profits. Now you can read the roadmap for implementing Six Sigma in your manufacturing or service organization.
The authorswho have worked with some of the most visible Six Sigma companies including GEprovide step-by-step guidance and practical implementation guidelines. Whether your goal is to fix a process problem or implement Six Sigma company-wide, The Six Sigma Way will help you develop an approach customized for your company's needs and the challenges of the twenty-first century business environment. The Six Sigma Way:Addresses the challenges and politics of launching, leading, and training people for Six Sigma. Focuses on implementing the major steps and quality improvement tools in the Six Sigma system. Features insights, comments, and examples from business leaders and managers using Six Sigma in their organizations.
Incorporating modern ideas, methods, and philosophies of quality management, Fundamentals of Quality Control and Improvement, Third Edition presents a quantitative approach to management-oriented techniques and enforces the integration of statistical concepts into quality assurance methods. Utilizing a sound theoretical foundation and illustrating procedural techniques through real-world examples, this timely new edition bridges the gap between statistical quality control and quality management.
The book promotes a unique "do it right the first time" approach and focuses on the use of experimental design concepts as well as the Taguchi method for creating product/process designs that successfully incorporate customer needs, improve lead time, and reduce costs. Further management-oriented topics of discussion include total quality management; quality function deployment; activity-basedcosting; balanced scorecard; benchmarking; failure mode and effects criticality analysis; quality auditing; vendor selection and certification; and the Six Sigma quality philosophy.
The Third Edition also features:
Presentation of acceptance sampling and reliability principles
Coverage of ISO 9000 standards
Profiles of past Malcolm Baldrige National Quality Award winners, which illustrate examples of best business practices
Strong emphasis on process control and identification of remedial actions
Integration of service sector examples
The implementation of MINITAB software in applications found throughout the book as well as in the additional data sets that are available via the related Web site
New and revised exercises at the end of most chapters
Complete with discussion questions and a summary of key terms in each chapter, Fundamentals of Quality Control and Improvement, Third Edition is an ideal book for courses in management, technology, and engineering at the undergraduate and graduate levels. It also serves as a valuable reference for practitioners and professionals who would like to extend their knowledge of the subject.