How To Implement Lean Manufacturing, 2nd Edition

Cutting-edge Lean manufacturing strategies

Thoroughly updated with the latest trends and new global case studies, How to Implement Lean Manufacturing, Second Edition, explains how to implement this powerful formula for eliminating waste, controlling quality and inventory, and improving overall performance across an enterprise environment. The book addresses the engineering and production aspects as well as the business culture challenges.

This practical guide describes the Toyota Production System (TPS) and specifies the distinct order in which Lean techniques should be applied to achieve maximum gains. By using the proven methods in this definitive resource, you can implement a successful Lean transformation in your organization. Find how to:

• Create and deploy enterprise-wide strategies and goals
• Improve speed and quality and dramatically lower costs
• Reduce variation in the manufacturing system in order to reduce inventory
• Reduce lead times to improve responsiveness and flexibility
• Sustain process gains
• Perform system-wide value-stream evaluations
• Manage constraints and reduce bottlenecks
• Implement cellular manufacturing

New material in the Second Edition reveals how to:

• Avoid the typical management pitfalls and implementation errors that virtually guarantee a Lean transformation will fail
• Implement the new skills of Lean leadership, including its six key elements
• Shape and manage your culture using the five cultural change leading indicators

Table of contents

1. What is the Perspective of this book
2. Lean Manufacturing and the Toyota Production System
3. Inventory and Variation
4. Lean Manufacturing Simplified
5. The Significance of Lead Time
6. Cultures
7. How to Do Lean – The Four Strategies to become Lean
8. How to Implement Lean – The Prescription for Lean Value Stream
9. Planning and Goals
10. Sustaining the Gains
11. Constraint Management
12. Cellular Manufacturing
13. The Story of the Alpha Line
14. The Story of the Bravo Line: A Tale of Reduced Lead Times
15. Using the Prescription – Three Case Studies
16. The Precursors to Lean not Handled Well
17. An Experiment in Variation, Dependent Events, and Inventory
18. Assessment Tools 19. A House of Lean