This book gives healthcare leaders a practical guide to implementing the 4 key components of lean daily management system - 1. LDM boards; 2. Leadership rounds 3. Leader daily disciplines and 4. Lean projects. Although lean is not new to healthcare, effective LDM is just now taking hold with the best lean healthcare organizations in the U.S. and Canada. Leaders are realizing that sustaining their lean projects over time has proven to be a challenge without first addressing the organizations management system/model. LDM gives leaders a straightforward approach to do just that as well as improve their ability to spread and deploy lean to other areas of the organization and tie back to strategy.

Building a Global Learning Organization: Using TWI to Succeed with Strategic Workforce Expansion in the LEGO Group describes how a multinational company developed a global structure for learning based on the TWI (Training Within Industry) program to create and sustain standardized work across multiple language and cultural platforms. In this book, Shingo Prize-winning author Patrick Graupp collaborates with two practitioners who performed the planning and implementation of the LEGO Group's worldwide Learning Organization.The book outlines the organizational and planning models used by the LEGO Group to create the internal ability to give and receive tacit skills and knowledge. Describing how and why TWI is used as the foundation for success in knowledge transfer across diverse languages and cultures, it provides step-by-step guidance on how to establish a solid organizational foundation for your own Learning Organization.Providing expert insight into the work of culture change, the book explains how to work with people to create motivation for moving to a new system of learning. It details the critical elements that made the implementation at the LEGO Group a success, identifies the stumbling blocks they encountered along the way, and explains how they were overcome. Case studies describe in detail what these efforts looked and felt like in actual application.The TWI program has long been recognized for its ability to generate results. After reading this book, you will gain valuable insight into how your organization whether large or small, national or international can integrate this timeless tool into your operating structure and your daily culture.

Winner of a 2012 Shingo Research and Professional Publication Award Demystifying the application of Lean methods, Lean Office and Service Simplified: The Definitive How-To Guide goes beyond the basic tools to detail the key concepts of Lean as they apply to office and service environments. It begins by discussing value stream management, followed by chapters on standard work, flow, level pull, and visual management.Winner of a 2012 Shingo Prize, this book covers essential Lean tools, including 5S and mistake proofing. It breaks down Lean concepts into their elementary components, describes them in a nonmanufacturing context, and supplies readers with specific how-to methodologies. Providing detailed examples throughout, the text illustrates the functions found in most service organizations, as well as the administrative areas of manufacturing companies.Drawing on more than two decades of practical experience, the author provides implementation strategies on a function-by-function and department-by-department basis. He examines the most common obstacles that readers are likely to encounter and supplies strategies to address those obstacles. The text includes a toolbox of helpful forms, charts, checklists, templates, and worksheets to help kick-start your Lean implementation efforts. Watch Shingo Prize-winning author Drew Locher discuss how to implement Lean concepts into your office and service settings.

How many IT books have you read that are long on theory and short on practical application? They are interesting, but not very impactful. They provide a framework from which to think and understand, but lack a process from which to act. Addressing this urgent need for the IT community, The Lean IT Field Guide explains how to initiate, execute, and sustain a lean IT transformation.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.

Updating the tools, principles, and methods presented in the bestselling first edition, this updated edition explains how to implement the authors proven improvement methodology that unifies the Theory of Constraints with Lean and Six Sigma. The book uses a compelling novel format to demonstrate how to achieve superior on-time delivery along with unprecedented levels of profitability.Besides explaining how to implement the authors unified improvement methodology, the book arms readers with a proven method for convincing management that using the improvement methodology outlined in the text will lead to significantly higher levels of profitability.This edition has been updated with an expanded appendix that includes more in-depth discussions of the tools covered in the first edition. This edition also sheds more light on the reasoning behind why the very best improvement results can be achieved by the unification of the Theory of Constraints, Lean, and Six Sigma (TLS). The appendix also provides additional detail about how the concepts covered in the book can be applied to your organization.The primary theme throughout this book is the focus on the unity and enhancement of improvement tools and methods. The book includes an appendix that allows readers to explore, in much more detail, the principles, tools, and techniques presented in the novel portion of the book.The authors detail a pioneering pathway for significant gains in profitability and market share for any company choosing to implement the methodologies that are presented. Some of the concepts, tools, and principles presented may seem counterintuitive to many readers, but if the principles are understood and followed, the exceptional results are sure to follow

Since the publication of its Shingo Prize-winning predecessor, TWI programs have seen steady growth in usage. As a true understanding of Standard Work has developed, the need for the TWI skills as fundamental tools to achieve Lean objectives has been solidified.The TWI Workbook: Essential Skills for Supervisors, Second Edition has been completely updated to the latest terminology and practice. This edition includes revised forms and tools, as well as new examples that illustrate current day TWI practice. Emphasizing the importance of accident and injury prevention, this edition includes an entirely new section on Job Safety, a fourth TWI module that was developed in Japan using the identical TWI methodology of the original three programs introduced in the original work. This updated edition includes new chapters on: Four Steps of Job Safety: Preventing Accidents before They Happen Two Key Aspects to Safety: Things and People Practicing the JS Method TWI's Problem Solving Training In addition to a new chapter on the TWI problem-solving methodology, this edition contains a new introduction with a more complete description of how TWI was reintroduced into American industry, including detailed information on the contribution TWI made at Toyota that was not available when the original book was published.Focusing on how the TWI skills create and support standardized work as the foundation for Lean and continuous improvement, the book includes detailed explanations on how to determine important steps and find key points that lead the way to standardized work. A new section on making a balanced breakdown has also been added, with new examples of Job Instruction breakdowns. The book also features a new conclusion that compares the historical role of TWI with what companies today are experiencing using the TWI methodology.

A Lean Safety Gemba Walk is a walk through the work area (Gemba) that focuses on the continuous improvement of safety. When conducted in a respectful manner, by skilled facilitators, Safety Gemba Walks can have a dramatic long-lasting impact on the culture of a business. Lean Safety Gemba Walks: A Methodology for Workforce Engagement and Culture Change is a follow-up to the author's bestselling book, Lean Safety, published in 2010. It is a natural progression from the philosophical overview provided by Lean Safety to the reality of the application of those principles in facilities around the world.This book presents a collection of Lean Safety Gemba Walk case studies that are based on the author's experiences over the last four years. As the stories unfold, readers are transported on a journey of discovery through the Gemba and begin to see safety differently just as those who physically participated. Illustrating the importance of employee engagement and culture change, the book provides you with the tools to engage managers, employees, and hourly staff in the continuous improvement of safety. The concepts covered will allow you to empower employees to make a difference in their safety culture rather than simply complying with safety rules.

Winner of a Shingo Research and Professional Publication Award 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 he

The problem with most Hoshin Kanri books is that they describe a complex methodology that is overwhelming to most leaders and their organizations. The need to essentially change the culture of the entire organization to make Hoshin work isn t practical for most companies when first starting out.The Basics of Hoshin Kanri uses an easy-to-follow story format to simplify and explain Hoshin Kanri a method for strategy deployment. Supplying clear descriptions of the steps of Hoshin Kanri, it advocates using Hoshin as an important tool for improving an organization s existing planning and execution system while simultaneously moving the culture of the organization forward.The book provides readers with a new understanding of Hoshin Kanri as a powerful deployment system for strategic planning, defining a direction and priorities, and aligning the organization around that direction. It begins by telling the story of a manufacturing executive that uses a simple Hoshin Kanri approach to make significant change in his personal life.Next, the book illustrates how this executive prepares to apply Hoshin Kanri to deploy strategy within his business. It concludes by presenting fascinating excerpts from the author s own interviews with experts in the field of Hoshin Kanri. All business leaders want their organizations to be "great" in all respects, but the reality is that they must get to "good" before they can consider becoming "great."

Mapping the Total Value Stream defines and elaborates on the concepts of value stream mapping (VSM) for both production and transactional processes. This book reshapes and extends the lessons originally put forward in a number of pioneering works including the popular ,Value Stream Management for the Lean Office. It reinforces fundamental concepts and theoretical models with real-world applications and complete examples of the value stream mapping technique. To educate VSM mappers on the specific mechanics of the technique, the text provides in-depth explanations for commonly encountered situations. 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.

Self-Balancing is not just a tweak or change to assembly line balancing, but a completely transformed method for achieving continuous flow. Among the reasons you should try Self-Balancing is that you can expect a productivity improvement of at least 30 percent with improvements of 50-60 percent quite common.Using a well-tested method for successful improvements initiated by the author, The Basics of Self-Balancing Processes: True Lean Continuous Flow is the first book to explain how to achieve continuous flow in both simple and complex manufacturing environments. It describes how to recognize and resolve weak links to ensure continuous flow in your manufacturing operations.The book offers rules, tools, and guidelines to help you not only solve problems at the root, but even eliminate them before they start. It reviews the shortcomings of traditional assembly line balancing and walks readers through the new paradigm of Self-Balancing.The text includes a comprehensive overview that demonstrates the power, flexibility, and breakthroughs possible with this method. Offering solutions to the shortcomings associated with standard line balancing including inventory buffers, variation, and operator pace it provides you with the tools and understanding required to deal with batch and off-line processes, debug your line, arrange your parts and tools, and design your own Self-Balanced cells. Watch Gordon Ghirann discuss how his book can increase the productivity of your business. http://www.youtube.com/watch?v=yte0622XbcI&feature=youtu.be

A Plan for Every Part (PFEP) is all about determining the right part at the right time, in the quantity needed. Turbo Flow: Using Plan for Every Part (PFEP) to Turbo Charge Your Supply Chain explains how to take this detailed inventory plan from the manufacturing arena and apply it to boost performance and cost efficiencies in your supply chain. It explains how to use PFEP to improve management of your raw materials, WIP, and finished goods inventories. Tapping into two decades of combined experience at Toyota Motor Manufacturing, the authors explains how to use PFEP to determine how much you need to build, the proper frequency for deliveries, how often you need to pick up from suppliers, and how much inventory you require. Presents an overview of PFEP for finished goods Discusses internal route planning and design using PFEP data Details external logistics and synchronization of manufacturing, logistics, and inventory cycles For those willing to fundamentally change the way they do business, this book will light the path to more efficient and profitable supply chain management.

Kaizen Events are an effective way to train organizations to break unproductive habits and adopt a continuous improvement philosophy while, at the same time, achieve breakthrough performance-level results. Through Kaizen Events, cross-functional teams learn how to make improvements in a methodological way. They learn how to quickly study a process, identify and prioritize improvement opportunities, implement change, and sustain their gains. Most importantly, they learn how to work with one another to solve problems rapidly and in a highly effective way.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.

TPM leads to soaring productivity when your operators are positively and energetically involved in the maintenance of their own equipment. Autonomous Maintenance for Operatorsteaches specific autonomous maintenance activities. For operators, supervisors, team leaders, and TPM coordinators, this book provides useful guidance and case study examples on autonomous maintenance. Activity boards, one-point lessons, photos, cartoons, and actual examples of implementation demonstrate the huge benefits of developing informed, motivated operators who take ownership of and improve their equipment. Shopfloor operators will learn: 4 skills they can develop to keep equipment running smoothly. how to inspect for problems as they clean equipment. ideas for containing debris that shortens equipment life. tips for effective lubrication management. how to use activity boards, meetings, and one-point lessons to promote TPM goals. This book assumes some familiarity with the steps of autonomous maintenance and focuses on specific autonomous maintenance activities.

For Florida Power and Light, Hewlett-Packard, and Texas Instruments, policy deployment has created a critical bridge between corporate goals and their company-wide deployment. Hoshin Kanri offers top and middle managers a guide to customizing a policy deployment program especially suited to their company. This book is a compilation of examples of policy deployment and demonstrates how company vision is converted into individual responsibility. It contains practical guidelines, 150 charts and diagrams, and five case studies that illustrate the procedures of Hoshin Kanri. The six steps to advanced process planning are reviewed and include: a five-year vision; one-year plan; deployment to departments; execution; monthly audit; and annual audit. The practice of Hoshin Kanri will enable you to: Align all departmental and individual project goals to corporate goals and eliminate duplication of effort. Communicate to every employee his or her role in achieving the company vision. Closely monitor performance using carefully devised measures of progress. Learn how Hoshin Kanri can increase your company's responsiveness to social, economic, and technical changes through flexible strategic management. (Originally published by the Japanese Standards Association)

El mejor libro sobre TPM que hemos editado hasta la fecha! El enfoque TPM resulta en mejoras dramaticas en calidad, costo de producci?n y entrega de productos. En este libro, nueve autores le ensenan todos los detalles que usted necesita para implementar el TPM, y ejemplos de industrias textiles, quimicas, de alimentos, entre otras. Una de las grandes ventajas de este libro es que le ayuda a conocer la implementacion del TPM a traves de la perspectiva de consultores especializados y reconocidos. Contenido: Vision general del TPM en las industrias de proceso Maximizacion de la eficacia de la producci?n Mejora orientada Mantenimiento Autonomo Mantenimiento planificado Gestion temprana Mantenimiento de calidad Promocion de tecnicas de operacion y mantenimiento TPM en los departamentos administrativos y de apoyo Creacion de un entorno grato y seguro Actividades de pequenos grupos TPM Medicion de la eficacia del TPM

Many shops have simplified their production control by using card-based systems such as kanban and Constant Work-in-Process (ConWIP). Although these systems provide a simple and highly effective visual approach for controlling manufacturing and service operations, all too many shops struggle with failed implementations or achieve results that fall below expectations. These outcomes can be attributed to a poor fit between the actual control problem and the solution applied.This book takes a different approach to most other books on the subject as it starts with an introduction to the control problem, instead of the control solution. Card-Based Control Systems for a Lean Work Design outlines how the problems encountered in typical manufacturing shops and service providers can be characterized, which allows for improved problem diagnosis.The first four chapters of the book lay the foundations for problem diagnosis. The next three chapters then discuss, in sequence, each of the three "traditional" card-based control systems: kanban, ConWIP, and Paired-cell Overlapping Loops of Cards with Authorization (POLCA). The book explains how each of these card-based control systems works and identifies the specific type of control problem to which each system applies.The next two chapters focus on Control of Balance by Card-Based Navigation (COBACABANA), a system developed for high-variety shops producing made-to-order, customized products. This is the first book to discuss this novel approach, which includes the use of cards to estimate due dates or delivery time allowances.The book closes with a framework that provides guidance on which system to apply. This framework contrasts the control problem with the control solution. The potential of combining card-based systems is also discussed to create a nested solution.

Most books about continuous and process improvement are written in a textbook format with straightforward information and plenty of graphs and charts to convey the points being made. Sometimes, even the best step-by-step instructions can escape even the most adamant of followers for an improvement method in determining exactly how to apply what they ve learned.Taking a different approach, Focus and Leverage is presented in an engaging business-novel format and is a sequel to the authors bestselling book, Epiphanized, Second Edition. The primary characters remain the same, but this time the storyline features two different industries: Maintenance, Repair, and Overhaul (MRO) and Healthcare (hospital) environments.This book expands and highlights the two improvement methods first introduced in the appendix section of Epiphanized: the Interference Diagram (ID)/Intermediate Objectives (IO) map (ID/IO Simplified Strategy) and Multiple-Drum-Buffer-Rope (M-DBR).Both of these innovative methods are the result of some much-focused thinking that allows for multiple improvement methods, and steps, to be combined into a single thinking process tool. This groundbreaking new method is designed to save time and money and allows faster and better results to be achieved.The two storylines move the reader through the necessary system analysis, problem identification, and solution implementation. The novel format aids in presenting several realistic situational discussions as well as a multitude of graphs and figures to explain the step-by-step process for success.The storyline of this book weaves some well-known and some not-so-well-known thinking tools into the problem-solving sphere to provide you with an understanding of how to first discover and then overcome issues not readily known or expected at the start of any project.

Although batching often appears more efficient than one-piece flow for individual tasks, the practice creates waste for other parts of the organization that more than offset its perceived benefits. A silent productivity killer, batching is an extremely difficult mindset to overcome and, as a result, numerous Lean initiatives have been destroyed by it.This book argues the case for one-piece flow over batching. It identifies the eight root causes of batching, the wastes created from batching, how batching drives the eight wastes, and the advantages of one-piece flow.One-Piece Flow vs. Batching: A Guide to Understanding How Continuous Flow Maximizes Productivity and Customer Value provides concrete arguments as to why batching, while sometimes necessary, is never the most efficient solution for most processes. It explains why flow, especially one-piece flow or continuous flow, should always be your ultimate objective when driving for increased productivity in any process.Using case studies to illustrate how to channel current mindsets toward one-piece flow as the preferred operation, the book is designed to support anyone involved in continuous improvement activities. It provides the tools and understanding you will need to overcome resistance to implementing flow and, in particular, one-piece flow processes whether it be on the factory floor or in a banking office.

By reconfiguring your traditional assembly lines into production cells based on one-piece flow, you can drastically reduce your lead time, staffing requirements, and number of defects. Kenichi Sekine studied under the late Shigeo Shingo and is responsible for many recent advances in the deployment of the Toyota Production System in Japan. In this comprehensive book, Sekine provides an in-depth education into the why's and how's of the restructuring process. Sekine first examines the basic principles of process flow building, then offers detailed case studies of how various industries designed unique one-piece flow systems (parallel, L-shaped, and U-shaped floor plans) to meet their particular needs. One-Piece Flow describes each step in the process of establishing one-piece flow and: (1) provides ample "test your skills" worksheets that guide you through the solution of problems, and (2) includes over 300 illustrations and 14 single-page case studies that show how to cut assembly personnel in various industries. With this book, plant managers will learn how to eliminate overstaffing waste and build a multi-skilled work force equipped to support JIT manufacturing. The book includes: Basic concept of one-piece production Case studies Process razing techniques U-shaped cells for assembly lines Techniques for removing waste from factories Establishing one-piece flow at a factory that produces small lots on a customer-order basis "Single" delivery at MYNAC

Written by two experts who have dedicated their careers to quality improvement, Escape the Improvement Trap: Five Ingredients Missing in Most Improvement Recipes separates itself from other improvement books by looking at why most companies rarely achieve anything more than an average level of improvement maturity. They identify five critical ingredients required for successful improvement: 1. A meaningful business value proposition and strategy that drives key improvement actions2. An engaging environment where people can do their best work3. A focus on meaningful metrics while avoiding irrelevant details4. Process improvement efforts that maximize cross-functional process performance and foster deeper process understanding, innovation, and execution of best work practices5. An executive mindset that focuses on customer value, people development, process performance, and business improvement outcomes, not solely on savings The authors consider a variety of situations at Independence Enterprise, a fictional company, based on their own very real experiences. They elaborate on the principles that should come into play, look at what Independence Enterprise is doing right and wrong, and suggest deployment actions to help you apply the principles to your own organization.

Quality has quickly become one of the most important decision-making factors for consumers. And although organizations invest considerable resources into building the right quality management systems (QMSs), in many instances, the adoption of such quality improvement tools are just not enough. Building Quality Management Systems: Selecting the Right Methods and Tools explains exactly what directors, practitioners, consultants, and researchers must do to make better choices in the design, implementation, and improvement of their QMSs.Based on the authors decades of industrial experience working on business improvement projects for multinationals looking to design or improve their QMSs, the book discusses building QMSs based on two important organizational elements: needs and resources. It begins with an overview of QMSs and systems thinking and the impact of QMSs on financial performance. Illustrating the process management approach, it reviews the most well-known business and quality improvement models, methods, and tools that support a major QMS.The authors introduce their own time-tested methodology for designing, implementing, and enhancing your own QMS. Using their proven method, you will learn how to: Implement a strategic quality plan based on your specific needs, capabilities, cost benefits, policies, and business strategies Select the right models, methods, and tools to be adopted as part of your QMS Understand the critical success factors and implementation challenges Evaluate the level of maturity of your QMS and your implementation efforts Highlighting the importance of quality as a way of life, this book supplies the understanding you'll need to make the right choices in the development and deployment of your QMS. With a clear focus on business performance and process management, it provides the basis for creating the quality management culture require

Visual Workplace/Visual Thinking (VWVT) was written by the acknowledged leading expert in workplace visuality. While other books touch upon visual workplace tools and practices, no other author has addressed the topic with the clarity and depth presented here. This is a seminal book, considered by many the definition of the field itself. First published by a small, independent press in 2005, the book won the prestigious Shingo Research Prize in the same year. It was then and remains the only book of its kind that describes the conceptual and practical foundation for workplace visuality, derived from dozens of hands-on implementations in some of the world's best or most challenging companies. Written not by an academic, but by a hands-on practitioner who has worked for three decades with companies in various phases of visual transformation, the work carries the reader from the usual starting point of 5S through to the full power of the visual-lean (R) alliance. The book's 11 chapters are in four sections. The first defines the visual workplace in relation to operational excellence, along with the eight building blocks of visual thinking. The next section, which targets the cultural conversion, is unexpectedly thrilling as it describes the genuine transformation of both company and employee which is at the heart of every visual conversion. Section 3 maps the logic and sequence of Dr. Galsworth's 10-Doorway template as you learn about the visual side of 5S, visual standards, visual scheduling, visual material control, visual metrics, visual problem-solving, visual leadership as well as the visual machine (R) and visual-lean (R)office. The final section of VTVW places visual management within the visual continuum, shows you how to use the ten doorways to assess your own company, and concludes with a discussion of the visual-lean alliance, illustrated through a conversion case study. With over 25 full-color albums of visual solutions, 50+ graphs and charts, a detailed table of contents and in-depth Index, this 277-page book positions the technologies of the visual workplace as a premier improvement strategy on every company's journey to operational excellence.

Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per hour.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.

In the global marketplace, no business is a self-contained island. No matter how effective your internal material movement, to be a future-thinking business, you must go to the next step and develop long-term supplier partnerships built on a dedication to continuous improvement and the basic concepts of Lean implementation. Lean Supplier Development: Establishing Partnerships and True Costs Throughout the Supply Chain provides step-by-step instruction on how to build partnerships of mutual improvement and success through supplier development. Offering the same advice that they have successfully applied to corporations across the globe, award-winning consultants Chris Harris, Rick Harris, and Chuck Streeter Provide criteria on how to choose suppliers that will make good long-term partnerships Demonstrate proven methods for employing Plan for Every Part (PFEP) to link your facility to the supply base Present a true cost model that eliminates guesswork when choosing suppliers to develop Show how to develop and maintain efficient information flow all along your supply chain Use real-world examples to cover likely contingencies Provide a sample quarterly supplier review that you can adapt for your own use Lean is a journey, not a destination. It requires flexible leaders at the helm who can readily adjust to ever-changing conditions and it requires like-minded partners all along the supply chain. Finding and developing these partners is not about good fortune, it is all about an uncompromising approach to continuous improvement and the application of systematic methods that will build working partnerships that broaden your definition of what is possible