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."
In plain-English writing, this friendly guide explores the general overview of Lean, how flow and the value stream works, and the best ways to apply Lean to your enterprise. You will understand the philosophy of Lean and adopt it not as a routine, but a way of life. This highly informative book teaches you:The foundation and language of Lean How to map the value stream and using it to your business’s advantage The philosophy of Kaizen Different tools to improve management, customer service, and flow and pull How to “Go Lean” within your business and across the industry Avoid common mistakes in implementation Seek out resources for assistance
This simple, continuous improvement approach that minimizes waste and adds customer value is changing organizations of all sizes all over the world. Lean for Dummies will show you to take charge and engage your enterprise in a Lean transformation!
Have you thought about using Lean in your business or organization, but are not really sure how to implement it? Or perhaps you're already using Lean, but you need to get up to speed. Lean For Dummies shows you how to do more with less and create an enterprise that embraces change. In plain-English, this friendly guide explores the general overview of Lean, how flow and the value stream works, and the best ways to apply Lean to your enterprise.
This revised edition includes the latest tools, advice, and information that can be used by everyone — from major corporations to small business, from non-profits and hospitals to manufacturers and service corporations. In addition, it takes a look at the successes and failures of earlier Lean pioneers — including Toyota, the inventors of Lean — and offer case studies and hands-on advice.The latest on the Six Sigma and Lean movements The role of technology and the expanding Lean toolbox Case studies enhance the material
Lean For Dummies gives today's business owners and upper level management in companies of all sizes and in all industries, the tools and information they need to streamline process and operate more efficiently.
Although PC-based flight simulations have been available for 30 years, many pilots, instructors, and flight schools don't understand how best to use these tools in real-world flight training and pilot proficiency programs. This invaluable reference bridges the gap between simulation tools and real-world situations by presenting hands-on, scenario-based exercises and training tips for the private pilot certificate and instrument rating. As the first of its kind based on FAA-Industry Training Standards (FITS), this book steers its focus on a scenario-based curriculum that emphasizes real-world situations.
Experienced pilot and author Bruce Williams ultimately aims to engage the pilot, reinforce the "realistic" selling point of PC-based flight simulations, while also complementing the FAA-approved FITS syllabi.Serves as essential reading for pilots who want to make effective use of simulation in their training while expanding their skill level and enjoyment of flying Covers private pilot real-world scenarios and instrument rating scenarios Includes a guide to recommended websites and other resources Features helpful charts as well as a glossary
You'll take off towards pilot certification with this invaluable book by your side.
Quality Control For Dummies is the straightforward, easy guide to improving your company’s quality. It covers all of today’s available options and provides expert techniques for introducing quality methods to your company, collecting data, designing quality processes, and more. This hands-on guide gives you all the tools you’ll ever need to enhance your company’s quality, including:Understanding the importance of quality standards Putting fundamental quality control methods to use Listening to your customer about quality issues Whipping quality control into shape with Lean Working with value stream mapping Focusing on the 5S method Supplement a process with Kanban Fixing tough problems with Six Sigma Using QFD to win customers over Improving you company with TOC
This invaluable reference is written from an unbiased viewpoint, giving you all the facts about each theory with no fuzzy coverings. It also includes steps for incorporating quality into a new product and Web sites packed with quality control tips and techniques. With Quality Control For Dummies, you’ll be able to speed up production, eliminate waste, and save money!
In today's time-crunched, cost-conscious global business environment, tight project deadlines and stringent expectations are the norm. Now with 25 percent new and updated content, Project Management For Dummies introduces you to the principles of successful project management and shows you how to motivate any team to gain maximum productivity.
You'll learn how to organize, estimate, and schedule projects efficiently and effectively. You'll also discover how to manage deliverables, issue changes, assess risks, maintain communications, and live up to expectations by making the most of the latest technology and software—and by avoiding common problems that can trip up even the best project managers.The latest information on measuring project management ROI and value to the organization (and customers) Managing Continuous Process Improvement Examples of formats used for different aspects of project management Managing distressed projects and managing multiple team projects Hierarchical decomposition and how it can dramatically improve the effectiveness of project planning and control The latest trend of embracing the use of social media to drive efficiency and improve socialization New information on managing and resolving conflicts that occur during a project Explanations of concepts tested in the PMP® certification exam with study tips and practices to help you pass
Project Management For Dummies gives professionals like you everything you need to be successful project managers.
(PMI, CAPM, PMP, and Project Management Professional are registered marks of the Project Management Institute, Inc.)
Being a manager can be an intimidating and challenging task. Managing involves teaching new skills to employees, helping land a new customer, accomplishing an important assignment, increasing performance, and much more. The process of management can be very challenging at times, but it can also bring you a sense of fulfillment that you never imagined possible.
Managing For Dummies, 3rd Edition is perfect for all levels of managers. This clearly written, easy-to-understand guide gives you practical advice on the most important aspects of managing, such as delegating as opposed to ordering, improving employees' performances, getting your message across, understanding ethics and office policies, team building and collaboration, and much more.Tips and advice for new and experienced managers All-new chapters on employee encouragement and corporate social responsibility Guidance on managing employees by leveraging the power of the Internet
Managing in today's lightning-speed business world requires that you have the latest information and techniques for getting the job done. Managing For Dummies, 3rd Edition provides you with straightforward advice and up-to-the-minute strategies for dealing with anything that comes your way.
If you're a business owner or an employee who manages finances, the latest edition of Bookkeeping For Dummies is for you. This handy guide gives you clear and concise information on how to keep track of accounts, prepare balance sheets, organize ledgers or journals, create financial statements, and so much more. Packed with the most up-to-date bookkeeping practices, tax information, and small-business laws, Bookkeeping For Dummies is an accessible, invaluable resource you'll turn to again and again.
Accurate and complete bookkeeping is crucial to any -business owner—but jumping in headfirst without knowing your accounts from your balance sheets can confuse even the most astute businessperson. That's where Bookkeeping For Dummies helps! Written in the familiar and friendly tone that has defined the For Dummies brand for more than twenty years, this clear and comprehensive guide covers everything you'll encounter as you set out to tackle your company's books, ensuring you're on the right track and saving you tons of headaches along the way. So what are you waiting for? It's time to hit the books!Offers easy-to-follow instructions to keep track of your business' financial well-being Covers managing assets and liabilities Includes updated QuickBooks screenshots and Excel spreadsheets Provides guidance on producing balance sheets and creating financial statements
Whether you're just starting out with bookkeeping—or a bookkeeper who needs to brush up on your skills—Bookkeeping For Dummies sets you up for success.
Are you looking to make your organisation more effective and productive? If you answered "yes," you need to change the way it thinks. Combining the leading improvement methods of Six Sigma and Lean, this winning technique drives performance to the next level—and this friendly and accessible guide shows you how. The third edition of Lean Six Sigma For Dummies outlines the key concepts of this strategy and explains how you can use it to get the very best out of your team and your business.
The jargon-crowded language and theory of Lean Six Sigma can be intimidating for both beginners and experienced users. Written in plain English and packed with lots of helpful examples, this easy-to-follow guide arms you with tools and techniques for implementing Lean Six Sigma and offers guidance on everything from policy deployment to managing change in your organisation—and everything in between. Gives you plain-English explanations of complicated jargon Serves as a useful tool for businesspeople looking to make their organisation more effective Helps you achieve goals with ease and confidence Provides useful hands-on checklists
Whether you want to manage a project more tightly or fine-tune existing systems and processes, the third edition of Lean Six Sigma For Dummies makes it easier to achieve your business goals.
This friendly, practical, guide explains candlestick charting and technical analysis in plain English. In no time, you’ll be working with common candlestick patterns, analyzing trading patterns, predicting market behavior, and making your smartest trades ever. You’ll discover the advantages candlestick has over other charting methods and learn the secrets of combining it with other technical indicators. You’ll also get familiar with different ways to display and interpret price action, including trend lines, support levels, resistance levels, moving averages, and complex indicators. Discover how to:Construct candlestick charts Identify and interpret basic patterns Trade in bull and bear markets Work with complex patterns and indicators Avoid False signals Understand the components of market activity Deal with bullish or bearish single-stick, two stick, and multistick patterns Identify and interpret complex patterns Use indicators to determine the market Outperform the market in any conditions
Don’t know whether to grab the bull by the horns or just grin and bear it? Read Candlestick Charting For Dummies and get it right the first time.
Based on the author's personal experience with Toyota’s master teachers and with companies in the midst of great change, Andy & Me: Crisis & Transformation on the Lean Journey, now in its second edition, is a business novel set in a failing New Jersey auto plant focusing on the tribulations of Tom Pappas, the plant manager. The situations, characters, and plant politics will ring true with many readers.
In a cool, readable style, this highly popular work follows Tom's relationship with Andy Saito, a reclusive retired Toyota guru whom Tom persuades to help save his plant through the teaching of the legendary Toyota Production System (TPS).
On this journey, the reader learns that TPS is more than just a collection of tools; it entails a new way of thinking and behaving. Though Tom finds success — both in his plant and in his personal life — he learns from Andy that successful improvement is endless and eternal.This edition includes study questions after each chapter to support your learning and help you tell some of your own stories.
Pascal Dennis discusses the 2nd edition of his Shingo Prize-winning book Andy & Me.
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.
Just as he did with the bestselling ISO 9001 in Plain English Cochran has written a comprehensive yet easily understandable guide to ISO 9001:2015. ISO 9001:2015 in Plain English was written so that anyone at any level of the organization can get to the heart of the standard’s requirements and how they apply to the organization quickly and simply. Plus, Cochran shows what has changed between the 2008 and 2015 version.
This straightforward book is ideal for people who are new to ISO 9001:2015, experienced ISO coordinators who want to get more out of an established system as they transition to the new standard, and for employees who just need a basic understanding of what ISO 9001:2015 is and how it applies to them.
Cochran explains each of ISO 9001:2015’s sections and clauses using real-world examples and frequently asked questions.
Currently Americans spend a staggering $200 billion each year on prescription drugs. As Dr. Angell powerfully demonstrates, claims that high drug prices are necessary to fund research and development are unfounded: The truth is that drug companies funnel the bulk of their resources into the marketing of products of dubious benefit. Meanwhile, as profits soar, the companies brazenly use their wealth and power to push their agenda through Congress, the FDA, and academic medical centers.
Zeroing in on hugely successful drugs like AZT (the first drug to treat HIV/AIDS), Taxol (the best-selling cancer drug in history), and the blockbuster allergy drug Claritin, Dr. Angell demonstrates exactly how new products are brought to market. Drug companies, she shows, routinely rely on publicly funded institutions for their basic research; they rig clinical trials to make their products look better than they are; and they use their legions of lawyers to stretch out government-granted exclusive marketing rights for years. They also flood the market with copycat drugs that cost a lot more than the drugs they mimic but are no more effective.
The American pharmaceutical industry needs to be saved, mainly from itself, and Dr. Angell proposes a program of vital reforms, which includes restoring impartiality to clinical research and severing the ties between drug companies and medical education. Written with fierce passion and substantiated with in-depth research, The Truth About the Drug Companies is a searing indictment of an industry that has spun out of control.
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. ...
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 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
"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
The book provides an overview of the function of the pharmaceutical microbiologist and what they need to know, from regulatory filing and GMP, to laboratory design and management, and compendia tests and risk assessment tools and techniques. These key aspects are discussed through a series of dedicated chapters, with topics covering auditing, validation, data analysis, bioburden, toxins, microbial identification, culture media, and contamination control.Contains the applications of pharmaceutical microbiology in sterile and non-sterile productsPresents the practical aspects of pharmaceutical microbiology testingProvides contamination control risks and remediation strategies, along with rapid microbiological methodsIncludes bioburden, endotoxin, and specific microbial risksHighlights relevant case studies and risk assessment scenarios
Illuminating a clear path to lean IT, the authors integrate more than two decades of combined experience to provide you with a proven method for creating and sustaining a true lean IT workplace. This field guide not only highlights the organizational techniques of more agile and lean processes, but also the leadership work required to help management adopt these new approaches.
Based on proven methods from different industries, including banking, manufacturing, insurance, food and beverage, and logistics, the book details a clear model that covers all the components you need to achieve and sustain a favorable work environment and culture in support of lean IT.
Filled with anecdotes and case studies from actual businesses, the book includes pictures, templates, and examples that illustrate the application of the lean methods discussed.
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.
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
Positioning Lean as a management operational philosophy far beyond the traditional set of improvement tools, the book explains how managers at all levels of the organization can integrate Lean into their daily management activities. It defines the Lean philosophy as well as the beliefs and behaviors required to develop a thriving Lean company culture.
The book captures the essence of Lean learning and Lean doing and illustrates practical applications of Lean management. It begins by covering the basics that encompass Lean management and leadership in two critical areas: maintenance/control and improvement.
After reading this book, you will better understand how to see waste, measure waste, eliminate waste, and develop an active change improvement workplace. You will also gain the practical understanding required to determine which Lean tool is best suited to your particular need for supporting an organization-wide management system.
Expounding on essential Lean concepts, this is an ideal guide to help new managers and leaders make the transition from theory to successful application in the field. Complete with brief summaries and examples of the most important tools in Lean management systems development in each chapter, the book provides a reliable roadmap for deploying a Lean management system across your organization, and subsequently across your entire value stream.
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.
Lean Connections: Making Information Flow Efficiently and Effectively isdesigned to help you rethink the way your organization views information flow. It provides the building blocks of a comprehensive information-flow system, showing you calculations and methods that will allow you to get the necessary information to those individuals who need it, when they need it.
Following a logical and detailed progression, this manual shows how to make information flow in lean production facility—
From the end customer through materials control to the production floor On the production floor at the operator, team, and value stream level And then from the production floor to the management of the facility
Employing a workbook format, this manual follows RNA Manufacturing, a fictional company, through its implementation of a comprehensive lean production system. As the authors outline RNA’s methods and thought processes, they employ exercises that ask questions about your own production system. Your challenge is to think deeply about the answers, as well as the changes that need to be made to effectively make information flow through your facility.
Make certain that everyone gets the information that they need when they need it
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.
This updated edition of a Shingo Research Award recipient begins with an overview of Lean methods. It explains how Lean practices can help reduce various frustrations for caregivers, prevent delays and harm for patients, and improve the long-term health of your organization.
The second edition of this book presented new material on identifying waste, A3 problem solving, engaging employees in continuous improvement, and strategy deployment. This third edition adds new sections on structured Lean problem solving methods (including Toyota Kata), Lean Design, and other topics. Additional examples, case studies, and explanations are also included throughout the book.
Mark Graban is also the co-author, with Joe Swartz, of the book Healthcare Kaizen: Engaging Frontline Staff in Sustainable Continuous Improvements, which is also a Shingo Research Award recipient. Mark and Joe also wrote The Executive’s Guide to Healthcare Kaizen.
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.
Identify development waste Assess an organization’s current state and develop a Current State Map Apply Lean principles to create a Future State Map
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.
The primary layout of the handbook follows the ASQ Body of Knowledge (BoK) for the Certified Six Sigma Green Belt (CSSGB) updated in 2015. The authors were involved with the first edition handbook, and have utilized first edition user comments, numerous Six Sigma practitioners, and their own personal knowledge gained through helping others prepare for exams to bring together a handbook that they hope will be very beneficial to anyone seeking to pass the ASQ or other Green Belt exams.
In addition to the primary text, the authors have added a number of new appendixes, an expanded acronym list, new practice exam questions, and other additional materials
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.
The prediction of failures involves uncertainty, and problems associated with failures are inherently probabilistic. Their solution requires optimal tools to analyze strength of evidence and understand failure events and processes to gauge confidence in a design’s reliability.
Reliability Engineering and Risk Analysis: A Practical Guide, Second Edition has already introduced a generation of engineers to the practical methods and techniques used in reliability and risk studies applicable to numerous disciplines. Written for both practicing professionals and engineering students, this comprehensive overview of reliability and risk analysis techniques has been fully updated, expanded, and revised to meet current needs. It concentrates on reliability analysis of complex systems and their components and also presents basic risk analysis techniques. Since reliability analysis is a multi-disciplinary subject, the scope of this book applies to most engineering disciplines, and its content is primarily based on the materials used in undergraduate and graduate-level courses at the University of Maryland. This book has greatly benefited from its authors' industrial experience. It balances a mixture of basic theory and applications and presents a large number of examples to illustrate various technical subjects. A proven educational tool, this bestselling classic will serve anyone working on real-life failure analysis and prediction problems.
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.
Quality guru John Oakland’s famous TQM model, in many ways a precursor to these frameworks, has evolved to become the ultimate holistic overview of performance improvement strategy. Incorporating the frameworks that succeeded it, the revised model redefines Quality by:
Oakland’s popular, practical, jargon-free style, along with ten case studies eight of which are brand new, effortlessly ties the model to its real-life applications, making it easy to understand how to apply what you’ve learned to your practices and a achieve sustainable competitive advantage.
Total Quality Management and Operational Excellence: Text with Cases (Fourth Edition)is supplemented for the first time with a suite of online teaching aids for busy tutors. This exciting update of a classic text is perfect for all students studying for professional qualifications in the management of quality, or those studying science, engineering or business and management who need to understand the part TQM may play in their subjects.
Rising costs are making healthcare unaffordable for millions, and 100,000 people die every year due to medical error. Healthcare must change–dramatically. Many leading healthcare institutions are discovering a powerful toolset for addressing both quality and cost: Six Sigma. In this hands-on, start-to-finish guidebook, four leading experts introduce Six Sigma from the unique standpoint of the healthcare professional, showing exactly how to implement it in real-world environments.
Drawing on their unsurpassed experience, the authors offer step-by-step methodologies, tools, and metrics–all thoroughly adapted to the unique realities of healthcare. They demonstrate how to utilize Six Sigma’s Define, Measure, Analyze, Improve, and Control (DMAIC) process to address even the most challenging problems. They also offer realistic guidance on rolling out Six Sigma initiatives that deliver rapid and sustainable value.
The authors show Six Sigma at work in every area of the hospital: clinical, radiology, surgery, ICU, cardiovascular, laboratories, emergency, trauma, administrative services, staffing, billing, cafeteria, even central supply. You'll learn why Six Sigma can produce better results than other quality initiatives, how it brings new rigor and discipline to healthcare delivery, and how it can be used to sustain ongoing improvements for the long term.
· Adapting Six Sigma methodology, tools, and measurements for healthcare
· Designing more successful experiments
· Rolling out your Six Sigma initiative successfully
· Case studies from every area of the hospital, from the ICU to billing
· Six Sigma templates modified fully for the healthcare environment
Comprehensive and user-friendly, this book will be indispensable to everyone concerned with quality or cost: administrators, managers, physicians, and quality specialists alike. Where Six Sigma is already in use or being considered, it will serve as a shared blueprint for the entire team.
Quality Function Deployment (QFD) techniques have helped thousands of organizations deliver higher-quality, more user-focused product designs. Now, Lou Cohen’s classic guide to QFD has been thoroughly updated to fully align QFD with Design for Six Sigma (DFSS) and other state-of-the-art Six Sigma methodologies.
Revised by world-class Six Sigma expert Joe Ficalora and his team at Sigma Breakthrough Technologies, this new edition’s up-to-date perspective on QFD reflects dozens of successful Six Sigma and DFSS deployments. They offer a start-to-finish methodology for implementing QFD, and systematically illuminate powerful linkages between QFD and Six Sigma, DFSS, Marketing for Six Sigma (MFSS), and Technology for Six Sigma (TFSS). An expanded, start-to-finish case study demonstrates how QFD should function from all angles, from design and marketing to technology and service.
Learn how to
Identify the roles and advantages of QFD in today’s global business environment Understand every element of the House of Quality (HOQ) Use QFD to drive more competitive product and service development Move from the processes you have to the processes you want Anticipate QFD’s unique challenges, overcome its obstacles, and deploy it successfully Extend the HOQ concept all the way through project completion Deploy powerful Voice of the Customer (VOC) techniques throughout all phases of development, not just planning Adapt QFD for software development, service development, and organizational planning Whether you’re working in operations, engineering, marketing, technology, or service development, this book will help you drive maximum value from all your Six Sigma, QFD, VOC, and DFSS investments.
In The Kaizen Event Planner: Achieving Rapid Improvement in Office, Service, and Technical Environments, authors Karen Martin and Mike Osterling provide a practical how-to guide for planning and executing Kaizen Events in non-manufacturing settings, and conducting post-Event follow-ups to sustain the improvements made.
Geared to continuous improvement professionals and leaders within the office areas of manufacturing, the service sector and knowledge-worker environments, this book provides the methodology and practical tools for generating measurable results, while building a motivated workforce and laying the foundation for continuous improvement.
The Kaizen Event Planner provides those responsible for improving office, service, and technical processes with the skills to effectively scope the activity, engage the right people, and facilitate successful Events!
An accompanying CD provides immediate access to a number of Excel-based tools.
In this insightful book, IT veteran Dave Zwieback shows you an approach for making postmortems blameless, so you can focus instead on addressing areas of fragility within systems and organizations. If you’re involved with assessing why something goes wrong on a project or at your company—as a system administrator, developer, team manager, or executive—the concrete steps in this guide will help you find a real solution that works.Recognize and mitigate the effects of stress during outagesLearn how to communicate effectively in a charged, high-stakes postmortem conversationCollect the necessary data before the postmortem beginsFocus on determining the actual causes and conditions of an outageLearn techniques for writing up a postmortem for either internal or external use
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
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.
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
In The Ice Cream Maker, Chowdhury uses a simple story to illustrate how businesses can instill quality into our culture and into every product we design, build, and market. The protagonist of the story is Peter Delvecchio, the manager of a regional ice cream company, who is determined to sell its ice cream to a flourishing national grocery chain, Natural Foods. In conversations with the Natural Foods manager, Peter learns how the extraordinarily successful retailer achieves its renowned high standard of excellence, both in the services it provides its customers and in the foods it manufactures and sells. Quality, he discovers, must be the mission of every employee; by learning to listen, enrich, and optimize, he can encourage and sustain the highest levels of quality in everything the company does.
Like Fish! and Who Moved My Cheese? The Ice Cream Maker offers an essential and universal lesson about one of industry's foremost challenges in a thoroughly engaging style. For managers and executives, small business owners and entrepreneurs, The Ice Cream Maker is a compelling, eye-opening guide to the most effective ways to achieve excellence and become industry leaders on the global stage.
From the Hardcover edition.
Successful development and commercialization of new products are critical to the long term viability of any business. The primary goal of product development is to enable a company to meet its goals for profitability and growth by introducing new, improved and innovative products to the market. The failure of a company to commercialize valuable new product ideas results in the commoditization of that company's product portfolio and potential failure of the business itself.
In this short cut we examine the business reasons that lead a company to adopt and implement the Design for Six Sigma methodology. During our discussion we examine the product life cycle that all products undergo, beginning with product development and ending with product decline. The impact of new, disruptive technologies on current products is also examined and illustrated with a case study example involving the replacement of vacuum tube technology by the transistor.
In addition, an examination of the economics of new product introduction is presented, describing the impact of low priced substitute and "surpriser and delighter" products on existing markets. Using traditional supply/demand economic analysis in combination with the Kano model, the authors explain the dynamic forces which move existing products from premium pricing to a state of commoditization. Finally, the authors take a detailed look at the financial metrics used to measure success in a DFSS project. During this portion of the chapter the authors discuss financial metrics such as Net Present Value; key reasons for failed commercialization programs; and the use of financial sensitivity analysis, including Monte Carlo simulation techniques.
This short cut describes in detail how DFSS brings value to companies. Using the language of business, the authors outline how Design for Six Sigma helps companies identify the needs of customers and emerging product trends through the use of a well defined, structured process. The authors also provides the reader with an understanding of how DFSS can be used to counter the forces of product commoditization and the entry of potentially disruptive technologies in the markets served by the business today.
What This Short Cut Covers 3
The Product Life Cycle 4
Where Have All the Vacuum Tubes Gone? 5
Understanding Dynamic Markets: The Kano Model 8
The Role of DFSS 12
Six Sigma Financial Metrics 14
Candy Wrapper Film: A DFSS Case Study 15
How to Measure Success in a DFSS Project 16
What's in the Book Commercializing Great Products with Design for Six Sigma? 36
About the Authors 45
Related Publications 46