Lean Performance ERP Project Management: Implementing the Virtual Lean Enterprise, Second Edition Book

Figures     xi
Foreword     xv
Preface     xxvii
Acknowledgments     xxxvii
About the Author     xli
Introduction to Lean Performance
Foundations of Lean Performance     3
When the ERP Project Manager Is the Lean Champion     3
The Organizational Consequences of Mass Production     8
The Origin of Lean Production     10
What Is Lean Production?     14
Why Aren't More Firms Lean?     16
What Is Required to Become Lean?     18
Extending Lean Performance Foundations     21
Implementing Lean Cross-Functional Processes     21
Lean Quality Management     23
Lean Maintenance     24
Lean New Product Introduction     25
Lean Design and Engineering     26
Lean Accounting     27
Lean Performance Methodology     33
What Is the Virtual Lean Enterprise?     33
Lean and ERP: Why Can't We All Just Get Along?     35
The Failure of ERP Implementations     42
Lean and Six Sigma     44
Why Should Our Enterprise Be Lean?     45
The Three Levels of Lean Business Process Management     49
LeanBusiness Process Strategic Level: Lean Policy Deployment     50
Lean Business Process Organizational Level: Lean Process Innovation     53
Lean Business Process Activity Level: Lean Performance Implementation     62
What Is Lean Performance?     66
How Does Lean Performance Improve Processes?     68
Why Lean Performance Is the Best Lean Methodology     69
Lean Cross-Enterprise Processes     81
What Is Lean Commerce?     81
Lean Customer Relationship Management     88
Lean Production Smoothing     90
Lean Supply-Chain Management     100
Lean Performance China Strategy     103
Supporting a Lean Factory Flow     104
Toyota Production System and Lean Commerce     108
Implementing a Virtual Lean Enterprise     110
Lean Principles, Tools, and Practices     113
Lean Cultural Principles     113
Process-Oriented Thinking Means What Before How     115
Product Quality Results from Process Quality     115
Every Process Needs a Process Standard     116
The Process Owners and Operators Are the Process Experts     117
The Next Process Is Your Customer     119
Loyalty to People Enables Continuous Improvement     119
Process Data and Measurements Drive Process Continuous Improvement     122
Lean Cultural Principles Checklist     122
Process-Oriented Thinking Means What Before How     122
Product Quality Results from Process Quality     123
Every Process Needs a Process Standard     124
The Process Owners and Operators Are the Process Experts     125
The Next Process Is Your Customer     126
Loyalty to People Enables Continuous Improvement     126
Process Data and Measurements Drive Process Continuous Improvement     128
Lean Transformational Principles     129
Precisely Specify Value by Product or Family     129
Identify the Value Stream for Each Product     129
Make Value Flow Without Interruption     129
Let Customer Pull Value from the Process Owner     129
Pursue Perfection     129
Lean Transformational Principles Checklist     130
Precisely Specify Value by Product or Family     130
Identify the Value Stream for Each Product     130
Make Value Flow Without Interruption     131
Let the Customer Pull Value from the Process Owner     131
Pursue Perfection     131
Lean Diagnostic Tools     132
3 MUs     132
5 Ss     137
5 Ws-1 H     142
4 Ms     146
Lean Performance Practices     152
Management Policy Deployment     152
Lean Performance Teams     154
Visual Management     155
Lean Performance Analysis     155
Steering a Lean Performance Project     161
Management in the Lean Performance Project     161
Advocate     162
Champion     162
Sponsor     162
Communicator     162
Motivator     163
Team Builder/Team Player     163
Educator/Developer     163
Change Agent     163
Facilitator/Coach/Catalyst     164
Mediator/Negotiator     164
Completing the Lean Performance Assessment     166
Lean Performance Assessment     167
Lean Enterprise Future State     167
In Our Future Lean Enterprise     171
Enterprise Lean Vision Elements (Add/Change to Fit Your Lean Enterprise)     172
Our Process Owners (Managers and Supervisors)     173
Company Readiness     173
Opportunity to Make Lean Applications     176
Company Capability to Become Lean     177
Lean Performance Project Constraints     180
Analyzing Lean Performance Assessment Results     183
Preparing for the Lean Performance Project     184
Lean Performance Planning Modules
Deploying Management Policy Module     189
Management Tasks     189
Organizing the Steering Committee     189
Confirming the Lean Vision     191
Identifying and Deploying Lean Business Policies     191
Identifying and Deploying Lean Project Strategies     192
Defining the Project Mission     195
Defining the Project Scope     196
Setting Up the Project Organization     197
Identifying and Deploying the Project Objectives     199
Conducting Steering Committee Meetings     203
Evaluating and Selecting Software Module     209
Management Tasks     212
Organize the Software Evaluation and Selection Project Team     212
Project Team Tasks     213
Organize the Project Office and Conference/Education Room     213
Determine Key Lean Software Features Workshop Attendees     213
Review All Lean Strategy/Policy/Project Objectives LPA Masters      214
Conduct Process Area Workshops     214
The 9 Forms of Office MUDA Checklist     215
The 5 Ss in the Office Checklist     216
The Office 5 Ss Checklist     217
5 Ss in the Computer Room Checklist     219
Conduct Key Lean Software Features Workshops     220
Process Stream Key Lean Features Checklist     221
Prepare a Draft of the Key Lean Software Features Checklist     223
Report Progress to Management Steering Committee     223
Managing Project Module     229
Project Team Tasks     229
Maintaining the Project Summary Bar Chart     229
Maintaining Project Communications     229
Maintaining the Project Plan     230
Maintaining an Open Issues Resolution Process     230
Maintaining the Project Organization     235
Maintaining the Quality Assurance Process     236
Reporting Progress to the Steering Committee     239
Developing Lean Performance Teams Module     241
Project Team Tasks     241
Finalizing Projects and Strategies     241
Developing the Site Configuration     242
Identifying All Processes     244
Developing Site Teams      254
Developing Lean Performance Team Training     254
Reporting Progress to the Steering Committee     265
What Follows Lean Performance Planning?     265
Lean Performance Improvement Modules
Improving Process Performance Module     273
Management Tasks     273
Maintaining Lean Performance Teams     273
Conducting Steering Committee Meetings     274
Project Team Tasks     275
Lean Performance Team Education     275
Human Resource Team Tasks     278
Finance Team Tasks     286
Engineering Team Tasks     288
Materials Team Tasks     292
Operations Team Tasks     294
Information Team Tasks     296
Lean Commerce Team Tasks     299
Completing Lean Performance Analysis     304
Challenging Processes Checklist     320
Producing Work Instructions     329
Integrating Systems Module     337
Project Team Tasks     337
Installing Hardware and Software     337
Initiating the System     338
Setting Up System Security     338
Creating Test and Training Environments     339
Creating Production Databases      339
Testing System Setup     339
Managing the Data Conversion Process     339
Evaluating Additional Software Packages and Interfaces     340
Conducting Process-Oriented System Design     342
Summarizing Proposed Modifications     342
Completing Hardware and Communications Analysis     344
Preparing Detailed Design Specifications     344
Managing Outsourced Programming     345
Defining Interface and Database Testing     346
Testing Improved Processes Module     347
Project Team Tasks     347
Objectives of Testing     347
Prototype and Pilot Testing     348
Establishing the Test Team     348
Test Team Kick-Off Meeting     355
Process Test     356
Stress Test     360
Process Workflow and Work Instruction Update     361
Conducting the User Training Program     362
What Follows Lean Performance Improvement?     362
Continuous Lean Performance Modules
Implementing Improved Processes Module     365
Management Tasks     365
Maintaining Lean Performance Teams     365
Implementing Lean Performance Management      368
Continuously Deploying Lean Policy and Strategy     372
Auditing Lean Performance     374
Project Team Tasks     376
Completing the Implementation Readiness Assessments     376
Verifying System Integration     377
Counting Down to Implementation     377
Implementing Improved Processes     378
Providing Additional Training     378
Providing Production Start-Up Support     378
Continuously Improving Lean Performance Module     379
Project Team Tasks     379
Defining and Initiating Lean Performance Measurements     379
Continuously Improving Lean Performance     385
Deploy Management Policy     387
Deploy Information Process Technology     388
Identify Processes and Teams     388
Complete the Lean Performance Analysis     388
Build New Information System Supports     389
Complete Updated Process Standards     389
Continuously Improve Lean Performance     389
Index     391