The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success


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Companies are increasingly embracing lean production techniques in their efforts to improve performance. Update: July Green Production is an organizational strategy that focuses on profitability through using environmentally friendly operating processes. The prime purpose of Green Production is to reduce environmental impact of manufacturing process at every stage and have three fundamental objectives:.

Here is the link of more information on this subject. A daily routine at gemba that involved examining rejects made the previous day before the work begins so that countermeasures can be adopted as soon as possible, based on gemba-gembutsu principles. Click here for a good discussion on this subject. Companies that attempt lean management find that lean methodologies are not transformable by themselves. The methodologies are sound, but for lean to work, employees must believe it is how they should do business on a daily basis.

Click here for the definition of lean culture. Lean thinking is a highly evolved method of managing an organization to improve the productivity, efficiency and quality of its products or services. Japanese and American management specialists developed the ideas and methods over the latter half of the last century. These management techniques have been employed both in the aerospace industry Boeing and in the auto sector Toyota.

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In the manufacturing sector, the concept is sometimes referred to as World Class manufacturing or High Performance Manufacturing. Prepared by. Annalisa L. Update: March Visual management is used to show how we are managing and measuring our business. Visual Management is certainly one of the characteristic traits that set lean organizations apart from all others.

The success of Visual Management is predicated on relevant and current data. To be effective, Visual Management must be embraced and utilized by leadership, management, and employees throughout the organization. Any process has inputs that can be controlled using visual management. The outputs can display performance, method, layout and status of a production cell in a clear, simple visual form.

The following link is a sample of how this idea works in lean organizations.

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Over the past few decades, several corporate improvement initiatives or programs have been developed to aid corporations in achieving external productivity excellence, most notably Lean Manufacturing and Six Sigma. Our experts lead this discussion on the proven strategies, tools, and techniques necessary to build a successful and sustainable ergonomics program that combines Lean Manufacturing and Six Sigma methodologies while also achieving bottom-line results. By integrating theses methodologies, your organization becomes a stronger business partner to all stakeholders by providing:.

Click here for more information look for the following research link from Institute of Industrial Engineers.

John Shook: Understanding Lean Transformation / Fókuszban a lean transzformáció

After we got a few feed backs from our web users, we are going to add new words to our website Glossary. Five rules of golden rules of gemba management are: 1 Go to gemba , 2 check gembutsu , 3 take temporary measures on the problems, 4 find and eliminate root cause 5 and finally standardize to prevent recurrence. Introducing good housekeeping in gemba reduces the failure by 50 percent, and standardization further reduces the failure rate by 50 percent of new figure.

A method for managing resources in gemba. Hiyari KYT refers to the practice of anticipating danger in advance and taking steps to avoid it. A diagram originally developed by professor Kaoru Ishikawa to show causes process and the effect result. The diagram is used to determine the real cause s and is one of the seven basic tools of problem solving. A device that stops the machine whenever the defective product is produces.

This device is essential in introducing JIT.

The Lean Manager: A Novel of Lean Transformation

Major concepts that must be understood and practiced in implementing kaizen are as following:. A standardized problem-solving procedure to be used at each level of organization. Kaizen story has eight steps: 1 select a project, 2 understand current situations and set objectives, 3 analyze data to identify root causes, 4 establish countermeasures, 5 implement countermeasures 6 confirm the effect 7 standardize, and 8 review the above process and work on the next steps. Manufacturing operations can be divided between machine hours and man hours. Kosu refers to the specific man hours it takes to process one unit of a product in a given process and is calculated by multiplying the number of workers involved in a process by the actual time it takes to complete the process, and dividing that by the units produced.

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Kosu reduction is of the key measures of productivity improvement in gemba. A daily routine at gemba that involves examining rejects gembustu made the previous day before the work begins so that countermeasures can be adapted as soon as possible, based on gemba-gembutsu principles. This meeting involving the gemba people and not staff in held first thing in the morning.

Flexible Approaches to Implementing Lean Manufacturing. Some alternative approaches are beginning to help companies implement Lean Manufacturing improvements quickly, inexpensively, and without overburdening staff resources. This article will briefly describe four new approaches being pioneered in an effort to make Lean implementation available to all companies regardless of their financial situation or personnel constraints. No matter what approach you take to becoming Lean, allow yourself and your staff to enjoy the process.

Few events in manufacturing are as exciting or dramatic as radically improving your workplace and the camaraderie of good people eagerly engaged in making the company better and stronger for everyone. In practical terms, an important area of business functioning is selected for rapid improvement to achieve defined goals and objectives.

The "team" participates in a brief but convincing training session and demonstration of Lean principles, after which they are released to the shop floor to begin work as usual. The facilitator and assistant then get very busy progressing through a discovery process examining the target area and every aspect of its functioning. When the team and management agree upon a clear vision of improvements needed, a plan is developed to implement the improvements at the earliest opportunity. Normally, full implementation will require an hr. This approach works particularly well when companies have reduced staff or are simply too busy to slow or shut down production for extended periods.

These funds are typically used to "invest" in local companies for the collateral benefits gained for local and state economic development.

The Going Lean Fieldbook

Implementing Lean Manufacturing techniques throughout the company while transferring "Lean Expertise" to the in-house "Improvement Manager" trainee s is the goal of this program. Hours of instruction are conducted in a primarily hands-on fashion as the Lean expert teaches, coaches, and collaboratively implements various aspects of Lean Manufacturing throughout the company. Trainees are given improvement assignments and are mentored through this process in an intensive four to six month undertaking that makes Lean experts out of existing staff.

This approach eliminates the need for increasing head-count, implements the majority of the "big bang" Lean techniques, and insures deep level understanding and capabilities of the trainee s. After the training period, the expert level "Improvement Manager s " guides the company through new improvement initiatives as needed without further outside support. The "Lean Right Now" approach exemplifies engaging in the implementation of real improvements with a diverse team made up of committed individuals from throughout the company to affect significant change very quickly. Emphasis is placed on strategic, tactical employment of Lean tools that increase throughput and reduce waste almost immediately.

Typically, this approach will require the full-time efforts of people for five days to achieve full implementation in a single area or concern. When creatively engaged and empowered, "Blitz Teams" routinely achieve incredible results using this approach.


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Manufacturers should be able to produce and sell the cost-effective product. High quality with low cost will give a company cutting edge over its competitors. A company with solid foundation of quality, minimal waste, innovative products and processes and quick response to customers demand or flexibility will be able to trim the product costs.


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JIT practices minimize the use of costly buffers e. Thus, unit cost of production is expected to decrease Ahmad et al. The best practices for cost reduction are inventory reduction, kanban and JIT purchasing.

HR practices can be conceptualized as the glue that holds the other Lean production practices together Longoni et al. JIT environments can be characterized as dynamic systems requiring awareness and management of change processes. There is evidence to suggest that the combination and emphasis of the overall human resource strategy employed in the JIT environment are potentially more important than the individual elements Power and Sohal According to McNamara , Lean manufacturing has failed to consider human aspects in the past, resulting in undesirable working conditions that can negatively affect commitment, and goes on to identify the role human behaviour plays in the performance of operating systems.

This paper focused specific attention on HRM practices having impact on cost, quality, delivery and flexibility.

The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success
The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success
The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success
The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success
The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success The Going Lean Fieldbook: A Practical Guide to Lean Transformation and Sustainable Success

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