Since the success of products significantly depends on the quality of product performance, inadequate management of the product design process can lead to improper performance of products that can result in significant long-term business losses. Design for Profitability: Guidelines to Cost Effectively Manage the Development Process of Complex Products presents a design guideline for complex product design and development that enables you to cost-effectively improve the technical performance of your products and consequently improve your competitiveness in the marketplace as well as improve profitability. The book helps you improve the competitiveness of your organization in the market and eventually improve profitability. It presents a mobile robots design guideline based on an empirical study of the mobile robots design process. This is an unprecedented guideline based on the empirical investigation of the internal aspects of the design process of complex products for cost-effectively enhancing the competitiveness in the market. The book also presents a hybrid lean-agile design paradigm for mobile robots. In addition, it points out key approaches and risks to manage the product development process efficiently. In designing complex products and integrated systems, industrial designers face a dilemma of cost-effectively striking a balance between product development time and product performance attributes. This book shows how and when value is added in product design and development through identifying statistically the most and least correlated design activities and strategies to product performance attributes. Introducing a new paradigm in the field of engineering design, the book gives you key approaches to efficiently manage the product development process.

For decades, 5S practitioners have struggled with exactly how to implement and sustain a 5S program in their workplaces. While there are many books available on the organization methods suggested by 5S, few provide easy-to-understand, step-by-step guidance on how to set up and sustain successful 5S implementations. 5S Made Easy fills this need.Written by an expert whose focus for the last decade has been nothing but 5S, the book supplies in-depth guidance on how to implement and sustain each of the 5S pillars'sort, set in order, shine, standardize, and sustain.The book uses an easy-to-follow format that was designed for use during 5S events. It provides color images of real-world 5S solutions, including before and after pictures from the field. It also supplies readers with online access to all of the forms and documents needed for an effective 5S program. All the forms and documents are provided in an easily editable format to fit any operation.

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

A facilitator has been traditionally defined as someone who helps a group of people understand their objectives, and assists them in planning to achieve them, without taking a position in the discussion. Recently, the International Standards Organization's (ISO's) implementation and other long-term, multi-year team involvement has challenged neutrality in all cases and has created a new type of facilitator, the results facilitator.The Results Facilitator: Expert, Manager, Mentor identifies the skills, training, and education that today's facilitators must possess. Outlining the new role of the facilitator, it presents powerful tools and techniques that can help facilitators achieve success. Continuous learning is a must and should follow the model-Learn-Practice-Evaluate-Act.The book demonstrates the use of Critical Success Factors (CSFs) for measuring progress toward achieving the objectives of a long-term program. It also supplies authoritative guidance on how to effectively plan, conduct, and complete meeting responsibilities. What can go wrong for a facilitator is outlined and methods to eliminate or mitigate these undesired situations are shown.The text details the core competencies that have been established by the International Institute for Facilitators (INIFAC) as well as the International Association of Facilitators (IAF). It shows where improvements can be made in each and recommends a joint IAF and INIFAC effort to consolidate into one facilitator's competency list.The book explains the need for an additional phase to the Tuckman's Group Dynamic Model. It shows several coaching processes including how to use the Toyota Production System's Kata for team improvement. The chapters have a facilitator exercise at the ends to help the reader apply their new knowledge to build their confidence and knowledge.

Making IT Lean: Applying Lean Practices to the Work of IT presents Lean concepts and techniques for improving processes and eliminating waste in IT operations and IT Service Management, in a manner that is easy to understand. The authors provide a context for discussing several areas of application within this domain, allowing you to quickly gain insight into IT processes and Lean principles.The text reviews IT Service Management, with reference to the IT Infrastructure Library (ITIL) as a framework for best practices explaining how to use it to accommodate Lean processes and operations. Filled with straightforward examples, it provides enough modeling tools so you can start your Lean journey right away. Examining the work of IT from an IT practitioner perspective, the book includes coverage of: The OM Perspective considers the work of IT from an Operations Management (OM) perspective, showing how many of the concepts that have been successfully applied within manufacturing can be applied to IT The Lean Improvement Model explains Lean concepts and practices and details the authors Lean improvement model Lean Problem-Solving (Identifying and Understanding Problems) considers operational work in IT and explains how to apply Lean practices related to problem identification and root cause analysis Lean Problem-Solving (Identifying and Managing Solutions) describes how to use good problem identification as the basis for identifying the right solutions Lean IT Service Management examines IT work from an IT Service Management perspective, using the ITIL framework as a guide Implementing and Sustaining Lean IT Improvements explains how to implement and sustain Lean IT improvements Throughout the book, the authors use a simple model for Lean Improvement as the framework

The Japan Institute of Plant Maintenance defines safety as the maintenance of peace of mind. Without peace of mind, or the serenity brought about by a safe working environment, employees will be unwilling and even unable to focus their energies on production improvement. Thus, it can be said that all improvement begins with safety. Winner of a 2013 Shingo Research and Professional Publication Award!A how-to manual on the proper integration of safety and environmental sustainability with Lean implementations, Lean Sustainability: Creating Safe, Enduring, and Profitable Operations provides a proven recipe for achieving safety and sustainability excellence. This book is the result of the author's two decades of experience implementing Lean; Safety, Health, and Environmental (SHE); and sustainability processes in the chemical, food, and consumer products industries. It unveils valuable lessons learned and little-known tips for eliminating waste and increasing process efficiency while reducing safety incidents and the overall impact on the environment.The text illustrates how to use the SHE Pillar as a gateway to continuous improvement, regardless of the improvement methodology you use. Bolstered with proven methodologies and real-world advice, it introduces novel approaches for achieving safety and sustainability excellence, including: Autonomous Safety'supplying employees with the knowledge, skills, and motivation to work safely Triple Zero the achievement of zero accidents, zero environmental incidents, and zero losses Green Value Stream Mapping the application of Value Stream Mapping to environmental and sustainability issues Although there are many books on Lean, sustainability, and SHE, few explain how to integrate these dynamic tools. Walking you through this process, this book supplies the tools to create a synergy that wil

Si usted quiere entender como se origino el sistema de producci?n Toyota y por que tiene exito, debe leer este libro. Aqui encontrara una introducci?n avanzada del justo a tiempo. El mundo le debe mucho a Taiichi Ohno. Nos ha demostrado como fbricar con mayor eficacia, como reducir costos, como producir una mayor calidad, y a examinar atentamente como nosotros, en nuestra calidad de seres humanos, trabajamos en una fbrica. El relato que Ohno cuenta en este libro es brillante. Deberia ser leido por todos los gerentes. No es solo un relato acerca de la fabricaci?n; sino tambien sobre como dirigir exitosamente una empresa.

At last, this much anticipated book has been published and provides a much needed breath of fresh air. The Strategos Guide to Value Stream and Process Mapping has helpful tips on facilitating group VSM exercises and helps put VSM in the greater Lean context. With photos and examples of related Lean practices, the book focuses on implementing VSM, not just on drawing diagrams and graphs. This is the most comprehensive and practical book on the subject to date.

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

There is a seismic shift underway in the employer/employee relationship that is redefining the nature of jobs and careers. Sole proprietors and independent contractors now represent more than 20 percent of the workforce, and that number is expected to reach nearly 50 percent within the next 10 years.Despite the proliferation of people engaging in freelance and contract work, however, the path to success is not always easy. Free Agent: The Independent Professional's Roadmap to Self-Employment Success details a pragmatic action plan to help you succeed in this new skills marketplace.Supplying practical strategies to help you get ahead of the change and become an in-demand resource with a steady stream of income, the book describes how work is changing and what is driving the growth of freelancing. Next, it explains how to get your new independent venture off the ground, how to find your first client, and what you need to know to avoid common pitfalls.To transition successfully from employee to free agent, you must have a plan to avoid the pitfalls and a support team to give you the expertise on complicated topics such as business structure, contracts, and accounting. This book is your guide to successfully navigating the transition.Detailing the tools and practices that will enable you to succeed as a free agent, the book includes case studies and interviews with those who have already made the transition. The book concludes by describing how to optimize your new freelance work style to make the most of your time and energy, so you can focus on doing more of what you love.

In an environment where many organizations think of human capital assets as little more than expense items that impact the bottom line, this book will help human resource (HR) professionals initiate a shift toward a new culture in which management views employees as true partners in achieving organizational success.The Field Guide to Achieving HR Excellence through Six Sigma provides detailed guidance on how to utilize the Six Sigma methodology and the TLS Continuum to achieve the business model that is required to thrive in today's business environment. The book demonstrates a clear path to continuous improvement that is based on the practice of spreading quality throughout the organization so that it becomes everyone's responsibility.This book is the sequel to Achieving HR Excellence through Six Sigma. In this book, Daniel Bloom provides a road map on how to implement the concepts found in the first book.The book begins by explaining how to create an HR Center of Excellence and then provides an understanding of the define-measure-analyze-improve-control (DMAIC) process and its implementation for HR. This road map will help you determine where your organization is failing to meet the voice of the customer.The book presents proven Six Sigma solutions for initiating and sustaining organizational change as well as strategies that allow leadership to make adjustments to processes if your organization falls short of meeting the need of the customer. It includes case studies of organizations that have successfully utilized the Six Sigma methodology to improve workflow and correct HR issues including the actual project documents used to implement the methodology.A word of caution: If the reason you are looking to improve work flow is to find ways to reduce headcount, then this is not the book for you. Instead, if you are looking for a guide that can help you become a strategic partner, administrative expert, employe

Mastering Complexity is designed to help readers develop and maintain logical, adaptable solutions to business problems. It demonstrates how to visualize business dependency connections with a square spreadsheet called a Dependency Structure Matrix (DSM). Once the links representing dependencies are visualized in a DSM, it can be used to improve the business. The book focuses on simple practices that the reader can easily understand to solve business problems on his or her own. The book begins by identifying how logical elements are represented in a DSM spreadsheet. It shows where the elements can run in parallel, where the elements must run in sequence, and where the elements are tangled together. The book shows how to untangle these elements so they can be understood. The book then demonstrates how to build a dependency map in a DSM spreadsheet. It defines the various types of dependencies and shows how to order the spreadsheet elements to create a workflow. The author shows how to assign risk levels to the spreadsheet elements so a workflow can be optimized to manage risk. The book concludes with a look at several software tools that can be used to create, manipulate, and analyze DSM spreadsheets. It discusses how the tools work and where they can be ordered.

Workshop leaders play a central role in your company's efforts to implement TPM. Once your workers have been divided into small groups to learn the fundamentals of TPM, it is the group leader who spearheads ongoing training and implementation activities. With quick-reading, people-oriented practicality, this new book addresses the role of the workshop leader in maximizing the benefits of TPM.A top TPM consultant in Japan, Kunio Shirose: Incorporates cartoons and graphics to convey the hands-on leadership issues of TPM implementation Uses case studies to reinforce his ideas on training and managing equipment operators in the care of their equipment Itemizes specific activities that must be undertaken to search out, correct, and control defects to remedy equipment shortcomings. He also addresses the cooperative relationship necessary between maintenance and production and leaves you with an understanding of the three imperatives for successful TPM implementation to change the quality and functioning of the equipment, the way operators think about equipment, and the workplace. (Originally published by the Japan Management Association.)

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.

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

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)

Part of the Lean Tools for Healthcare series, this user-friendly book will help to improve your understanding of kaizen. It describes exactly what a kaizen event is and details all the phases necessary for implementing continuous improvement practices in your healthcare organization. Kaizen Workshops for Lean Healthcare walks you through the steps of conducting an effective kaizen workshop one that is well planned, well implemented, and well monitored. The information is presented in an easy-to-assimilate format. Numerous illustrations reinforce the text and margin assists call your attention to key terms, healthcare examples, and how-to steps. Throughout the book, you will be asked to reflect on questions that will help you apply the concepts and techniques in your own workplace. Defining the key concepts and elements of the "production" of healthcare services, the text delineates the differences between healthcare processes and the individual cycles of work that those processes link together. It also: Provides foundational information on kaizen and kaizen workshops defining the key roles for success Explains exactly how to plan and prepare Presents examples of how to present workshop results and how to follow up Includes a concise summary of kaizen workshop steps Supplies a list of additional resources for learning more about the different kinds of improvement methodologies you might want to implement in your kaizen workshops If your healthcare organization fully applies the steps detailed in this book, it will gain much more than the knowledge of how to conduct a workshop. Through kaizen, you will empower your employees to make positive change a reality. And incrementally, kaizen workshops will become more than isolated events they will become the way all work is done in your organization.

Lean Transformations for Small and Medium Enterprises: Lessons Learned from Italian Businesses summarizes two decades of research, teaching, and practice on lean thinking. Based on quantitative analysis of 100 cases of Lean transformations and 20 in-depth case studies of successfully transformed SMEs, it explains how to undertake lean transformations that lead to operational and financial performance improvement, and uses the Lean Transformation Framework --conceptualized by John Shook at the Lean Enterprise Institute as a practical approach to design and de-risk the transformation process. SMEs leaders wishing to undertake and sustain a lean transformation must: Make a serious and lasting commitment to transform, avoiding the temptation to change course of action; Choose accurately the value streams that require improvement as defined by strategy deployment; Build capabilities to sustain the transformation; Lead by example by going to gemba and creating a culture of respect for people that goes beyond the visible devices and artifacts of Lean tools.

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.

Hospitals and health systems are facing many challenges, including shrinking reimbursements and the need to improve patient safety and quality. A growing number of healthcare organizations are turning to the Lean management system as an alternative to traditional cost cutting and layoffs. "Kaizen," which is translated from Japanese as "good change" or "change for the better," is a core pillar of the Lean strategy for today's best healthcare organizations.Kaizen is a powerful approach for creating a continuously learning and continuously improving organizations. A Kaizen culture leads to everyday actions that improve patient care and create better workplaces, while improving the organization's long-term bottom line. The Executive Guide to Healthcare Kaizen is the perfect introduction to executives and leaders who want to create and support this culture of continuous improvement.The Executive Guide to Healthcare Kaizen is an introduction to kaizen principles and an overview of the leadership behaviors and mindsets required to create a kaizen culture or a culture of continuous improvement. The book is specifically written for busy C-level executives, vice presidents, directors, and managers who need to understand the power of this methodology. The Executive Guide to Healthcare Kaizen shares real and practical examples and stories from leading healthcare organizations, including Franciscan St. Francis Health System, located in Indiana. Franciscan St. Francis employees and physicians have implemented and documented 4,000 Kaizen improvements each of the last three years, resulting in millions of dollars in hard savings and softer benefits for patients and staff. Chapters cover topics such as the need for Kaizen, different types of Kaizen (including Rapid Improvement Events and daily Kaizen), creating a Kaizen culture, practical methods for facilitating Kaiz

While more and more companies are aggressively pursuing Operational Excellence by employing Six Sigma, Lean, and other continuous improvement methods, the concept has yet to be defined in a way that can be easily taught and applied, especially in industries other than manufacturing. This book fills that need.Beyond the Lean Office uses a compelling novel format to illustrate what it takes to create and sustain flow and Operational Excellence in the office. Readers learn as they follow the main character through initial attempts to correct late responses to a primary customer and the evolution to an approach based on Operational Excellence. The story illustrates the day-to-day issues that most organizations face in their pursuit of Operational Excellence.To achieve Operational Excellence, it takes more than just a strong leader with passion and drive. The key ingredient is practical knowledge that can be applied quickly and easily by following a process. This book supplies step-by-step guidance on how to move your office services from point A to point B. The practical insights and guidance presented here create a road map that can be shared with each employee to rapidly move your organization forward. All chapters also include a From the Author section that shares authoritative insights on the topic at hand.After reading this book, you will understand how to design and create self-healing flow that provides reliable, predictable output in the office and operates without the need for management intervention to deliver the services provided by the office. Instead, management focuses on the activities that grow your enterprise.

This is the Participant Guide to support team leaders in implementing an autonomous maintenance team. This is usually sold with Autonomous Maintenance: Shopfloor TPM Implementation. This is for extra copies.

This dictionary, specific to lean business processes, contains over 500 terms used in lean management and manufacturing. Easy to access, accurate, and comprehensive, LeanSpeak will become the desktop tool of choice for lean manufacturing practitioners, from the shop floor to the corner office. Here are some examples of entries in LeanSpeak: gemba: Japanese word of which the literal translation is "the real place." In the manufacturing field, gemba means the shop floor, where the actual product is being made, as contrasted to the office, where support services are provided. lean: shorthand to refer to a lean manufacturing system, of which the Toyota Production System is the foremost example, that has relatively little non-value-adding waste and maximum flow. The term has been used pejoratively to refer to anti-labor practices intending to reduce the number of workers within a company and to strong-arm tactics with suppliers. takt time: the rate at which product must be turned out to satisfy market demand. It is determined by dividing the available production time by the rate of customer demand. For example, if customers demand 240 widgets per day and the factory operates 480 minutes per day, takt time is two minutes. If customers want two new products designed per month, takt time is two weeks. It is a calculated number, not a reflection of your capability. It sets the pace of production to match the rate of customer demand. Also available as an ebook in Microsoft Reader, Adobe Acrobat Reader, or Palm Reader formats.

By simultaneously examining the concerns of design, production, purchasing, finance, and marketing from the very first stages of product planning, concurrent engineering makes doing it right the first time the rule instead of the exception. This should be the first book managers read when they are ready to eliminate waste in the product development process. An introductory handbook, it gives managers 16 clear guidelines for achieving concurrent engineering and contains abundant case studies of Japanese, U.S., and European company success stories. The book also: Defines the concurrent engineering task force as a full-time, multidisciplinary unit of operation. Discusses the necessary interdependence of concurrent engineering, Quality Function Deployment, Total Quality Control, and CAD/CAM. Shows how concurrent engineering can be structured to fit your company and used to gain flexibility and efficiency.

These 20 essential keys have helped many manufacturing companies integrate the top manufacturing improvement methods into a coordinated system for drastic and continual improvement in involvement, quality, and productivity. This program provides the strategies necessary to achieve ambitious goals through a five-level scoring system. The revised edition is improved with upgraded criteria for the system to guide your company to world-class status. New material and updated layout make implementation even easier. Two valuable case studies demonstrate effective use by both a Japanese company and an American manufacturer.