The Gold Mine deftly weaves together the technical and human pieces of implementing lean manufacturing in an engaging story that readers will find both compelling and instructive. Authors Freddy and Michael Ballé have produced the first integrated and systematic approach to a set of ideas that have maximized value and minimized waste throughout the world.
At the heart of The Gold Mine is Bob Woods, a curmudgeonly sensei coaxed out of retirement by his son Mike to help boyhood friend Phil Jenkinson save his struggling company. Despite terrific products and a backlog of orders, Phil's company cannot generate enough cash from its operations to pay its bills. And so Mike enlists Bob to help his pal fix this crisis.
“You're trying to deal with your mess as if it was a technical problem,” Bob tells Phil. “Move this machine here, change this design there, which it is to some extent, but … it's all about people. You have a leadership problem not just a production or business problem.” As Phil begins to tackle the key challenges necessary to improve his company's operations, he comes to understand the deeper points of lean. Readers will also draw powerful insights from his journey.
The Gold Mine presents all the key lean principles, ranging from well-known ideas such as pull and flow, to lesser-known yet equally important principles such as jidoka and heijunka. The book also reveals lean as a system—using a realistic story to show how the principles are interrelated and how they lead to useful tools such as kanban or 5S. Freddy Ballé draws from his authority of one of Europe's preeminent lean veterans, bringing his knowledge to life in the context of a dramatic human story of managers and employees struggling to apply these tools and ideas in a successful turnaround.
“Mastery of the technical details of lean thinking is never enough. A transformation will fail without the most important element: the engagement of the people doing the work,” says publisher James Womack. “The Gold Mine is the first book to comprehensively introduce all the lean tools by means of a vivid personal story showing how hearts and minds are won over. It will spark ah-ha's from everyone who has been there and provide profound insight for those who are just getting started. I can't recommend it highly enough as a way to teach your people the key lean tools that always lead to success while also teaching, in the words of Bob Woods, that 'it's all about people.”
“Reading The Gold Mine is like eavesdropping on a sensei dispensing gems to a client,” says co-publisher Daniel Jones. “The Ballés draw from a remarkable perspective of wisdom and experience. Readers, especially those individuals working on the shop floor, will gain revelation and inspiration by living through the experiences of the hero. This is an experiential novel that will resonate deeply with people who relate it to their own lives. Managers and executives just beginning a lean transformation will learn valuable insights about how to sidestep the technical and people problems that lay ahead. And experienced lean thinkers will discover fresh insights about overcoming resistance to change.”
While The Gold Mine represents LEI's first book of fiction, Womack envisions it as a natural complement to the workbooks that have established themselves as the leading guides for learning lean. “The Gold Mine was created on the premise that people have different learning styles, and that a set of ideas based on the shop floor—where the action takes place—can be grasped intuitively by illustrating how one particular company responds,” he says. “It complements our established products by presenting a different but equally vital method of sharing knowledge.”
Step inside any organization, even a very successful one, and you’ll probably find a lot of waste if you know where to look. From providing a feature that consumers don’t care about to exhausting efforts on tasks that only require adequate attention, there are countless areas where resources go down the drain. In Low-Hanging Fruit, Jeremy Eden and Terri Long provide seventy-seven of their most effective techniques for improvement, each drawn from their success working with major companies.
For more than twenty years, Jeremy Eden and Terri Long have helped companies of all sizes make millions by harvesting their low-hanging fruit. In this practical guide, Eden and Long share valuable, refreshing insights in entertaining chapters that get straight to the point. This book shows you how to smoothly shift your approach, your priorities, and your mindset to reveal the hidden potential in your organization. Whether you are a member of a small team or a global executive, you will learn how to identify and solve hidden problems, improve productivity, and increase profits.
Many people don’t realize that there are dozens of quick, easy, and affordable ways to make things better. Don’t buy into the myth that only some people have creative ideas. Typically, the people closest to the work (from the factory floor to the C-Suite) and the people closest to the customer know the best ways to improve business. We can pluck this “low-hanging fruit” every day to save time and money right away.
Need to grow your company’s earnings but don’t know where to find the low-hanging fruit? The answer is right in front of you, but harvesting it takes skill. Eden and Long show you seventy-seven clever ways to discover possibilities and make meaningful changes. Low-Hanging Fruit shows you how to easily improve your job satisfaction, your team’s performance, and your company’s earnings.
A comprehensive guide that cuts through the hodgepodge of copycat initiatives, overblown buzzwords, confusing mathematics, and misguided software, Factory Physics for Managers is a breath of fresh air for operations managers and executives.
Written by the leaders and experts behind the bestselling Factory Physics, it’s a brilliant crash course in the practical science of operations designed to help you:Achieve best possible profit, cash flow, and customer service Attain highest return with existing Lean, Six Sigma, and ERP initiatives Manage your capacity, inventory, response time, and variability with high predictability Simplify management of complexity using existing IT systems Use the fundamentals of science to ensure your operation’s success See your company and procedures more clearly Improve intuition, decision making, and strategy execution
A strategy of imitation is not much of a strategy. Most every company uses the common continuous improvement initiatives. This highly accessible guide addresses but goes beyond other business approaches such as Lean, Six Sigma, and Theory of Constraints by offering a customizable plan that you can apply to any manufacturing-based industry or supply chain.
You’ll discover invaluable tools for developing operations strategy and driving execution by using practical science to assess your procedures, target problems, and find solutions. You’ll learn essential life lessons from the best—and worst—practices of corporate leaders like Toyota and Boeing. You’ll find ingenious new ways to improve your leadership by predictively managing the tradeoffs that every operation faces—whether it’s more or less inventory or capacity, higher or lower customer service, or more or fewer products.
Using this approach, you can tackle these natural conflicts in business through a practical, comprehensive science of operations.
Factory Physics for Managers makes it easier to choose and execute the best strategy for better productivity—and even bigger profits.
Praise for Factory Physics for Managers
“Factory Physics for Managers is a proven path to flawless execution and results. Leading vs. following in our industry is predicated on the relentless pursuit of putting order to chaos. Factory Physics science and CSUITE software have given our organization the ability to plan, predict, model, and execute based on explosive growth and rapid-fire, dynamic changes to our business model. In our case, history is not a good predictor of the future, so we need to deploy our resources wisely, and the Factory Physics approach has helped us do just that.”
—Larry Doerr, COO, Stratasys
“Shows how the science behind Lean initiatives can greatly improve results in terms of productivity and resources.”
—Bill Fierle, Vice President and General Manager, TopWorx, Emerson
“Brings powerful, accessible science to operations management. The Factory Physics playbook enables me to lead the harnessing of our data more effectively for modeling, planning, control, and feedback. Armed with the concepts, common language, and tools in this book, I can partner with operations’ leadership to impact the bottom line.”
—Jeffrey Korman, CIO, Hu-Friedy Mfg LLC, Chicago
This practical guide from an experienced leader in business and operations management will change how you think, how you lead, and how your whole company operates. Addressing everything from strategy to innovation to leadership, it fuses traditional operational tactics such as efficiencies and supply chain management with customer, supplier and employee empowerment. This unique, integrated approach has proven to be the best approach to surviving in today’s tough market—and beating the competition at their own game.
Instead of looking for inspiration in other businesses’ best practices, Shawn Casemore urges you to seek ideas and solutions internally—by engaging sources internally and externally to your company in an effort to create a sustained vortex of business improvement. You’ll learn how to implement a structured approach to performance and productivity that disrupts the silo mentality, drives innovation, encourages collaboration all while empowering your employees—to reach even higher levels of operational performance.
Shawn Casemore (Owen Sound, Ontario) spent over seventeen years in leadership roles in Operations, Business Improvement and Supply Chain Management with Magna International, Arvin Meritor, Bellwyck Packaging, N.C.R. and Bruce Power. He currently is the Founder and President of Casemore and Co Incorporated.
"Bamford and Forrester have done an excellent job in creating a concise, salient, and appealing approach - they have captured the essential elements of designing processes, products and work organizations; exploring approaches to operations planning and control; managing change through effective project management and technology transfer; and then managing quality and improvement strategies".
—Professor Rob Handfield, Professor of Supply Chain Management, North Carolina State University, USA
"This is an excellent concise text that introduces students to all of the key areas - it's an invaluable aid for students in understanding all of the major aspects of operations and their importance to the success of businesses".
—Professor Steve Brown, Professor of Management, University of Exeter Business School, University of Exeter, UK
"For today's or tomorrow's business leaders this text has well structured invaluable content ready for immediate adoption. Follow the guide, put it into practice, and the rewards will follow".
—Mr Vernon Barker, Managing Director, First TransPennine Express, First Group Plc, UK
"This book combines technical theory 'book smarts' with real life experience 'street smarts' in a flowing read".
—Mr Stephen Oliver, Vice President Marketing & Sales, Vicor Corporation, Boston, USA
The Lean Manager: A Novel of Lean Transformation reveals how individuals can go beyond the short-term gains from tools, and realize a deeper, sustainable path of improvement. Full of human moments that capture the excitement and drama of lean implementation, as well as clear explanations of how tools and systems go hand-in-hand, this book will teach and inspire every person working to make lean a reality in their organization today.
This book will help you learn both the how of doing lean, as well as the why behind the tools, enabling you to become lean.
Lean is the most important business model for competitive success today. Yet companies still struggle to sustain enduring and deep-rooted business success from their lean implementation efforts.
The most important problem for these companies is becoming lean: how can they advance beyond realizing isolated gains from deploying lean tools, to fundamentally changing how they operate, think, and learn? In other words, how can companies learn to go beyond lean turnaround to achieve lean transformation?
The Lean Manager: A Novel of Lean Transformation, by lean experts Michael and Freddy Ballé, addresses this critical problem. As we move from what Jim Womack, author, lean management authority, and LEI founder, calls “the era of lean tools to the era of lean management,” The Lean Manager gives companies a definitive guide for sustaining their ability to learn and improve operations and financial performance, while continually developing people.
“The only way to become and stay lean is to produce lean managers,” says Womack. “Every isolated effort will recede—or fail—unless companies learn to use the lean process as a way of developing individual problem-solvers with the ownership, initiative, and know-how to solve problems, learn, and ultimately coach new individuals in this discipline. That’s why this book matters so much.”
The Lean Manager, the sequel to the Ballé’s international bestselling business novel The Gold Mine, tells the compelling story of plant manager Andrew Ward as he goes through the challenging but rewarding journey to becoming a lean manager. Under the guidance of Phil Jenkinson (whose own lean journey was at the core of The Gold Mine), Ward learns to use a deep understanding of lean tools, as well as a technical know-how of his plant’s operations, to foster a lean attitude that sustains continuous improvement.
Where The Gold Mine shows you how to introduce a complete lean system, The Lean Manager demonstrates how to sustain it. Ward moves beyond fluency with tools to changing his behavior as a manager and leader. He shifts from giving orders and answers to asking the right questions so people identify and address problems. He learns how to use tools to unleash the creativity and motivation of people, so they learn how to solve problems as well as coach and teach others to solve problems. Ward learns how to create lean managers.
“I am excited and have hopes that this book will enlighten readers about what it really means to live a business transformation that puts customers first and does this through developing people,” said Jeffrey Liker, author of The Toyota Way and professor of Industrial and Operations Engineering at the University of Michigan. “People who do the work have to improve the work. There are tools, but they are not tools for ‘improving the process.’ They are tools for making problems visible and for helping people think about how to solve those problems.”
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.
The latest Lexicon, updated in 2014, contains 60+ graphics and 207 terms from A3 Report to Yokoten. The Lexicon covers such key lean terms as andon, jidoka, kaizen, lean consumption, lean logistics, pull, plan-for- every-part, standardized work, takt time, value-stream mapping, and many more.
The new terms are:
• Basic Stability
• Gemba Walk
• Kamishibai Board
• Leader Standard Work
• Lean Management
• Lean Management Accounting
• Lean Startup
• Problem Solving
• Service Level Agreement
• Training Within Industry (TWI)
• Value-stream Improvement
Unlike most other business glossaries in print or online, the Lexicon, introduced in January 2003, is focused exclusively on lean thinking and practice.
Like the past four, the fifth edition of the Lean Lexicon incorporates terms and improvement ideas from our customers. We continue to welcome suggestions from the growing lean community in its traditional industries and beyond.
—Daniel H. Pink, author of To Sell Is Human and Drive
"The Ballé books are a great way to get started or to speed up your pace of transformation, personal and organizational."
—Jim Womack, Founder of Lean Enterprise Institute
In their new business novel Lead With Respect, authors Michael and Freddy Ballé reveal the true power of lean: developing people through a rigorous application of proven tools and methods. And, in the process, creating the only sustainable source of competitive advantage—a culture of continuous improvement.
In this engaging and insightful story, CEO Jane Delaney of Southcape Software discovers from her sensei Andy Ward that learning to lead with respect enables her to help people improve every day. “For us, lean is all about challenging yourself and each other to find the right problems, and working hard every day to engage people in solving them,” he says.
Lead With Respect’s timely message brings a new understanding of lean. While lean has become essential for companies to compete in today’s global economy, most practitioners see it as a rigorous focus on process to produce higher quality goods and services—a limited understanding that fails to realize the true power of this approach. This new novel by the Ballés, the third in a series that includes Shingo Research Award-winners The Gold Mine and The Lean Manager, breaks new ground by sharing huge amounts of practical information on the most important yet least understood aspect of lean management: how to develop people through a rigorous application of lean tools. You’ll learn:How to apply Lead With Respect attitudes to the lean tools you are using now so that you develop a truly sustainable lean culture.What specific steps to follow to make lean leadership behaviors daily habits.How to manage with respect through the emotion, conflict, tension, and self-doubt that you’ll face during a lean transformation.
The international bestseller The Toyota Way explained the company's success by introducing a revolutionary 4P model for organizational excellence-Philosophy, People, Process, and Problem Solving. Now, in Toyota Culture, preeminent Toyota authorities Jeffrey Liker and Michael Hoseus reveal how Toyota selects, develops, and motivates its people to become committed to building high-quality products-and how you can do the same for your company.
Toyota Culture examines the “human systems” that Toyota has put in place to instill its founding principles of trust, mutual prosperity, and excellence in its plants, dealerships, and offices around the world. Beginning with a look at the evolution of the Toyota culture and why its people are the heart and soul of the Toyota Way, the authors explain the company's four-stage process for building and keeping quality people: Attract, Develop, Engage, and Inspire.
Drawing upon numerous examples from Liker's decades of research as well as Hoseus' insider access as a Toyota manager, Toyota Culture gives you the tools you need to:Find competent, able, and willing employees Start training and socializing your people as you hire them Establish and communicate key business performance indicators at every level of your organization Train your people to solve problems and continuously improve processes in their daily work Develop leaders who live and teach your company's philosophy Reward top performance-and offer help to those who are struggling
Fascinating vignettes of Toyota's innovative culture highlight the nuances of translating and recreating a people-centric culture in factories and offices across the globe. These exclusive, behind-the-scenes details are just what your company needs to successfully learn from The Toyota Culture.