More than a guide to establishing a proposal system, this volume presents methods for teaching know-how. It gives each reader the principles for thinking creatively about improving his or her own work.

This highly practical book is filled with easily understood explanations and examples of how to teach your employees to pursue excellence through kaizen teian.

Before you can institute a successful kaizen teian program, you must have a firm understanding of its underlying principles and rules. This book concentrates on making those principles clear and focuses on the importance of consistently implementing proposals. Actual examples of implemented proposals from five leading Japanese companies illustrate the principles described, and numerous figures and case studies add clarity throughout. If you are ready to tap into the full potential of your work force, this book will help you to train them to seek out new and ever better ways to do their work.

The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample. This book introduces operators and assembly workers to the basic methodology of ZQC in an easy-to-read format that covers all aspects of this important manufacturing improvement strategy. Mistake-Proofing for Operators includes the instructional features that are the signature of the Shopfloor Series. In this series Productivity Press has taken the lead in adult education by teaming with instructional designers to develop complete programs for frontline learning. The goal: to place powerful and proven improvement tools such as ZQC and mistake-proofing in the hands of your company's entire workforce. Winner of the 1990 Shingo Prize for Excellence in Manufacturing, Mistake-Proofing for Operators is based on Zero Quality Control: Source Inspection and the Poka-Yoke System by Shigeo Shingo

The benefits of advanced manufacturing methods can't be realized until they're practiced consistently and proficiently by your entire workforce. Here's a simple, low-cost way to get everyone on board quickly. This small book presents the basic methodology of TPM and focuses on hands-on activities for shopfloor teams to maximize equipment effectiveness.

Feedback from our customers indicates that this book has been used primarily by shopfloor supervisors to lead operator teams in implementing TPM programs. For the most cost effective on-site education, every supervisor and team leader in your operation should read this book.

"TPM for Supervisors" offers an overview of the basic features of TPM as well as the implementation process in an easy-to-follow presentation. It focuses on the important role of supervisors in maximizing equipment effectiveness. For the most cost-effective on-site education, every supervisor in your operation should read this book. It presents the basic methodology of TPM in clear, accessible language and will help supervisors implement TPM improvement activities on the shop floor. It's the best way to ensure a companywide understanding of TPM.

Flow is a fundamental concept of lean manufacturing, and its improvement is a challenge to many organizations. After mastering basic visual tools, managers must concentrate on increasing flow. This work provides shopfloor and other lean professionals with what they need to know about how other companies are implementing and sustaining continuous flow improvement.

Improving Flow: Collected Practices and Cases provides a variety of case studies taken from articles previously published in the newsletter "Lean Manufacturer Advisor." The book demonstrates how to move products and services to the customer quicker while eliminating waste and improving profits.

In a "pull" production system, the final process pulls needed parts from the previous process, which pulls from the process before it, and so on, as determined by customer demand. This allows you to operate without preset schedules and avoid unnecessary costs, wastes, and delays on the manufacturing floor.

"Pull Production for the Shopfloor" introduces production teams and managers to basic pull production concepts, enabling them to begin understanding, planning, and implementing this lean tool. Use this book to get everyone on board to reduce work in process inventory, lead-time, and other profit-draining expenses. This book will enable plant managers to explain and thereby get support the support they need from higher management for their pull implementation efforts.

In this book you will learn about:

• Key concepts and applications of pull production
• The five steps to implementing a pull production system
• Production leveling
• Line balancing
• Managing pull production with kanban
• One-piece flow production
• Linking your suppliers to your pull production system

Productivity's Shopfloor Series books offer a simple, cost-effective approach for building basic knowledge about key manufacturing improvement topics. Like all our Shopfloor Series books, "Pull Production for the Shopfloor" includes innovative instructional features that are the signature of the Shopfloor Series. The goal: to place powerful and proven improvement tools such as pull production techniques in the hands of your entire workforce.

Key learning features include:

• Well-organized, and easy-to-assimilate learning
• Chapter overviews and summaries
• Questions throughout each chapter to help you apply the learning to your own workplace
• Drawings and illustrations
• Margin icons that flag definitions, main points, and other highlights

The philosophy of kaizen, which simply means continuous improvement, needs to adopted by any organization seeking to implement lean improvements that go beyond cost cutting. Kaizen events are opportunities to make focused changes in the workplace. Kaizen for the Shopfloor takes readers through the critical steps for conducting a very effective kaizen event: one that is well planned, well implemented, and well documented. As the newest addition to the Shingo Prize Winning "Shopfloor Series," Kaizen for the Shopfloordistills the complexities of jumpstarting lean processes into an easily accessible format for those frontline employees who make lean possible.

About the "Shopfloor Series": Put proven improvement tools in the hands of your entire workforce!

Progressive shopfloor improvement techniques are imperative for manufacturers who want to stay competitive and to achieve world class excellence. And it's the comprehensive education of all shopfloor workers that ensures full participation and success when implementing new programs. The Shopfloor Series books make practical information accessible to everyone by presenting major concepts and tools in simple, clear language and at a reading level that has been adjusted for operators by skilled instructional designers. One main idea is presented every two to four pages so that the book can be picked up and put down easily. Each chapter begins with an overview and ends with a summary section. Helpful illustrations are used throughout.

Other topics in the "Shopfloor Series": Kanban, 5S, Quick Changeover, Mistake-Proofing, Just-in-Time, TPM, Cellular Manufacturing

Are you ready to implement a just-in-time (JIT) manufacturing program but need some help orienting employees to the power of JIT? Here is a concise and practical guide to introduce equipment operators, assembly workers, and other frontline employees to the basic concepts, techniques, and benefits of JIT practices.
Like all our Shopfloor Series books, "Just-in-Time for Operators" presents concepts and tools in simple and accessible language. The book includes ample illustrations and examples to explain basic JIT concepts and some of the changes people may encounter in a JIT implementation.

• Key definitions
• Elimination of process waste
• Leveled production, kanban, and standard work
• U-shaped cells and autonomation
• JIT support techniques

The JIT approach is simple and universal -- it works in companies all over the world. Educating employees ensures their full participation and allows them to share their experiences and ideas more effectively.

Standard work is an agreed upon set of work procedures that effectively combines people, materials, and machines to maintain quality, efficiency, safety, and predictability. Work is described precisely in terms of cycle time, work in process, sequence, time, layout, and the inventory needed to conduct the activity. Standard work begins as an improvement baseline and evolves into a reliable method. It establishes the best activities and sequence steps to maximize performance and minimize waste. In this book you will learn about: The characteristics of standards Key benefits and applications of standardization Standard work concepts and calculations Standard work steps and documentation Using standard work manuals, charts, and worksheets Cell staffing (line balancing and full work) Productivity's Shopfloor Series books offer a simple, cost-effective approach for building basic knowledge about key manufacturing improvement topics. Like all our Shopfloor Series books, Standard Work for the Shopfloor includes innovative instructional features that are the signature of the Shopfloor Series. The goal: to place powerful and proven improvement tools such as pull production techniques in the hands of your entire workforce.

The benefits of advanced manufacturing methods can't be realized until they're practiced consistently and proficiently by your entire workforce. Here's a simple, low-cost way to get everyone on board quickly. This small book presents the basic methodology of TPM and focuses on hands-on activities for shopfloor teams to maximize equipment effectiveness. Feedback from our customers indicates that this book has been used primarily by shopfloor supervisors to lead operator teams in implementing TPM programs. For the most cost effective on-site education, every supervisor and team leader in your operation should read this book. TPM for Supervisors offers an overview of the basic features of TPM as well as the implementation process in an easy-to-follow presentation. It focuses on the important role of supervisors in maximizing equipment effectiveness. For the most cost-effective on-site education, every supervisor in your operation should read this book. It presents the basic methodology of TPM in clear, accessible language and will help supervisors implement TPM improvement activities on the shop floor. It's the best way to ensure a companywide understanding of TPM.

"Kaizen teian" -- the Japanese-style proposal system for continuous improvement -- is the most direct and effective method for channeling employees' creative energies and hands-on insight. This book is the first in a new three-volume set that brings the management, guidance, and development of kaizen teian systems into perfect focus.

This first volume explains many aspects of running a proposal program on a day-to-day basis and provides cartoon examples of successful kaizen teian programs in four major Japanese organizations. This concise reference outlines the policies that support a "bottom-up" system of innovation and defines the three main objectives of kaizen teian: to build participation, develop individuals' skills, and achieve higher profits. "(Originally published by Nikkan Kogyo Shimbun, Ltd.)"

Equipment downtime can bring a lean manufacturing operation to a complete standstill. Total productive maintenance (TPM) is such a fundamental part of becoming lean because a machine failure at one step of a continuous flow process will halt all the steps before and after it. Strategies aimed at eliminating downtime are essential in any operation in which the processes require the use of complex machinery and equipment. TPM: Collected Practices and Cases provides a variety of case studies taken from articles previously published in Lean Manufacturer Advisor: the monthly newsletter by Productivity Press.

In a "pull" production system, the final process pulls needed parts from the previous process, which pulls from the process before it, and so on, as determined by customer demand. This allows you to operate without preset schedules and avoid unnecessary costs, wastes, and delays on the manufacturing floor. Pull Production for the Shopfloor introduces production teams and managers to basic pull production concepts, enabling them to begin understanding, planning, and implementing this lean tool. Use this book to get everyone on board to reduce work in process inventory, lead-time, and other profit-draining expenses. This book will enable plant managers to explain and thereby get support the support they need from higher management for their pull implementation efforts. In this book you will learn about: Key concepts and applications of pull production The five steps to implementing a pull production system Production leveling Line balancing Managing pull production with kanban One-piece flow production Linking your suppliers to your pull production systemProductivity's Shopfloor Series books offer a simple, cost-effective approach for building basic knowledge about key manufacturing improvement topics. Like all our Shopfloor Series books, Pull Production for the Shopfloor includes innovative instructional features that are the signature of the Shopfloor Series. The goal: to place powerful and proven improvement tools such as pull production techniques in the hands of your entire workforce. Key learning features include: Well-organized, and easy-to-assimilate learning Chapter overviews and summaries Questions throughout each chapter to help you apply the learning to your own workplace Drawings and illustrations Margin icons that flag definitions, main points, and other highlights

Applying lean to the supply chain is a hot topic. While lean operations can produce significant benefits to an organization, the greatest benefits will not be realized unless lean is extended beyond the organization to involve both suppliers and customers. Lean Supply Chain: Collected Practices and Cases provides a variety of case studies taken from articles previously published in Lean Manufacturing Advisor -- the monthly newsletter by Productivity Press.

More than a guide to establishing a proposal system, this volume presents methods for teaching know-how. It gives each reader the principles for thinking creatively about improving his or her own work. This highly practical book is filled with easily understood explanations and examples of how to teach your employees to pursue excellence through kaizen teian. Before you can institute a successful kaizen teian program, you must have a firm understanding of its underlying principles and rules. This book concentrates on making those principles clear and focuses on the importance of consistently implementing proposals. Actual examples of implemented proposals from five leading Japanese companies illustrate the principles described, and numerous figures and case studies add clarity throughout. If you are ready to tap into the full potential of your work force, this book will help you to train them to seek out new and ever better ways to do their work.

Kaizen teian -- the Japanese-style proposal system for continuous improvement -- is the most direct and effective method for channeling employees' creative energies and hands-on insight. This book is the first in a new three-volume set that brings the management, guidance, and development of kaizen teian systems into perfect focus. This first volume explains many aspects of running a proposal program on a day-to-day basis and provides cartoon examples of successful kaizen teian programs in four major Japanese organizations. This concise reference outlines the policies that support a "bottom-up" system of innovation and defines the three main objectives of kaizen teian: to build participation, develop individuals' skills, and achieve higher profits. (Originally published by Nikkan Kogyo Shimbun, Ltd.)

Are you ready to implement a just-in-time (JIT) manufacturing program but need some help orienting employees to the power of JIT? Here is a concise and practical guide to introduce equipment operators, assembly workers, and other frontline employees to the basic concepts, techniques, and benefits of JIT practices. Like all Shop Floor Series books, Just-in-Time for Operators presents concepts and tools in simple and accessible language. The book includes ample illustrations and examples to explain basic JIT concepts and some of the changes people may encounter in a JIT implementation.Key definitionsElimination of process wasteLeveled production, kanban, and standard workU-shaped cells and autonomationJIT support techniquesThe JIT approach is simple and universal -- it works in companies all over the world. Educating employees ensures their full participation and allows them to share their experiences and ideas more effectively.

Flow is a fundamental concept of lean manufacturing, and its improvement is a challenge to many organizations. After mastering basic visual tools, managers must concentrate on increasing flow. This work provides shopfloor and other lean professionals with what they need to know about how other companies are implementing and sustaining continuous flow improvement. Improving Flow: Collected Practices and Cases provides a variety of case studies taken from articles previously published in the newsletter Lean Manufacturer Advisor. The book demonstrates how to move products and services to the customer quicker while eliminating waste and improving profits.

Standard work is an agreed upon set of work procedures that effectively combines people, materials, and machines to maintain quality, efficiency, safety, and predictability. Work is described precisely in terms of cycle time, work in process, sequence, time, layout, and the inventory needed to conduct the activity. Standard work begins as an improvement baseline and evolves into a reliable method. It establishes the best activities and sequence steps to maximize performance and minimize waste.

In this book you will learn about: The characteristics of standards Key benefits and applications of standardization Standard work concepts and calculations Standard work steps and documentation Using standard work manuals, charts, and worksheets Cell staffing (line balancing and full work)

Productivity's "Shopfloor Series" books offer a simple, cost-effective approach for building basic knowledge about key manufacturing improvement topics. Like all our "Shopfloor Series" books, Standard Work for the Shopfloor includes innovative instructional features that are the signature of the "Shopfloor Series." The goal: to place powerful and proven improvement tools such as pull production techniques in the hands of your entire workforce.

Applying lean to the supply chain is a hot topic. While lean operations can produce significant benefits to an organization, the greatest benefits will not be realized unless lean is extended beyond the organization to involve both suppliers and customers. Lean Supply Chain: Collected Practices and Cases provides a variety of case studies taken from articles previously published in "Lean Manufacturing Advisor" -- the monthly newsletter by Productivity Press.

Equipment downtime can bring a lean manufacturing operation to a complete standstill. Total productive maintenance (TPM) is such a fundamental part of becoming lean because a machine failure at one step of a continuous flow process will halt all the steps before and after it. Strategies aimed at eliminating downtime are essential in any operation in which the processes require the use of complex machinery and equipment.

TPM: Collected Practices and Cases provides a variety of case studies taken from articles previously published in "Lean Manufacturer Advisor": the monthly newsletter by Productivity Press.

The Lean Office: Collected Practices and Cases is a compilation of articles previously published in the Productivity Press newsletter, Lean Manufacturing Advisor. These articles discuss lean implementations in non-manufacturing operations, from design to processing invoices to customer service. Most articles are written in the form of case studies. Highlights include- Practical, in-depth description of lean implementation, written in a conversational, easy-to-read style A large quantity of case studies unavailable from any other single source Responds to your desire for real-world lean office information

Overall Equipment Effectiveness (OEE) is a crucial measure in TPM that reports on how well equipment is running. It factors three elements ---the time the machine is actually running, the quantity of products the machine is turning out, and the quantity of good output - into a single combined score. Directly addressing those who are best positioned to track and improve the effectiveness of equipment, OEE for Operatorsdefines basic concepts and then provides a systematic explanation of how OEE should be applied to maximize a piece of equipment's productivity and recognize when its efficiency is being compromised.

Features

The hard part of implementing a lean transformation, according to most experts, is dealing with the ""soft"" issues, such as culture change. Getting employees to live and breathe lean -- actively supporting and buying into lean concepts and philosophy, always searching for ways to eliminate waste, and continuously improving processes and providing greater value for customers -- is the real challenge when building and sustaining a lean culture.

"Lean Culture: Collected Practices and Cases" provides a variety of case studies taken from articles previously published in "Lean Manufacturer Advisor": the monthly newsletter by Productivity Press. All focus on cultural issues, ranging from the role of top management, to training and development of workers and managers, to building buy-in and to sustaining the culture.Highlights include: Practical, in-depth descriptions of cultural issues in a lean transformation, written in a conversational, easy-to-read style.Many case studies unavailable from any other single source.Articles categorized by specific area - all desired information is easily located.Real-world information about culture change collected in one handy book.

Kanban is the name given to the inventory control card used in a pull system. The primary benefit of kanban is to reduce overproduction, the worst of the seven deadly wastes. A true kanban system produces exactly what is ordered, when it is ordered, and in the quantities ordered. It is essentially a dynamic work order that moves with the material. Each kanban identifies the part or subassembly unit and indicates where each one came from and where each is going. Used this way, kanban acts as a system of information that integrates your plant, connects all processes one to another, and connects the entire value stream to customer demand. Kanban for the Shopfloor provides a working manual for those seeking to implement this method of production control in any operation. It defines the various terms and methods employed in kanbans, and illustrates how when adhered to, kanban is an element of continuous improvement that ultimately leads to the ideal of one-piece flow." In addition to reducing the waste of overproduction, kanban will help your company increase flexibility to respond to customer demand, coordinate production of small lots and wide product variety, and simplify the procurement process. About the Shopfloor Series: Put proven improvement tools in the hands of your entire workforce! Progressive shopfloor improvement techniques are imperative for manufacturers who want to stay competitive and to achieve world class excellence. And it's the comprehensive education of all shopfloor workers that ensures full participation and success when implementing new programs. The Shopfloor Series books make practical information accessible to everyone by presenting major concepts and tools in simple, clear language and at a reading level that has been adjusted for operators by skilled instructional designers. One main idea is presented every two to four pages so that the book can be picked up and put down easily. Each chapter begins with an overview and ends with a summary section. Helpful illustrations are used throughout. Other topics in the Shopfloor Series: Kanban, 5S, Quick Changeover, Mistake-Proofing, Just-in-Time, TPM, Cellular Manufacturing

Sort, Set in Order, Shine, Standardize, Sustain. Together, these five simple principles form the basis of the 5S System - a powerful front-line tool for simplifying work processes, improving equipment maintenance, ensuring safety and product quality and eliminating waste. 5S is the basis for any on-the-floor improvement activity and the 5S for Operators Learning Package is a fantastic way to bring that knowledge to the shop floor. Thorough, flexible and almost infinitely customizable, the 5S for Operators Learning Package allows your instructor to conduct learning sessions tailored specifically to your organization. That customizability combined with modules specifically designed to encourage workers to become actively involved in the learning process makes for a high-impact learning experience your workforce won't soon forget. Based on the classic manufacturing text 5 Pillars of the Visual Workplace, the 5S for Operators Learning Package brings that knowledge to the shop floor and will prove to be an excellent support in your companies' continuous improvement efforts. The 5S for Operators Learning Package contains: A Leader's Guide 5 copies of 5S for Operators A CD with additional presentation materials A copy of 5 Pillars of the Visual Workplace