Lessons from a Lean Consultant: Avoiding Lean Implementation Failures on the Shop Floor Book

Preface     xv
Acknowledgments     xvii
About the Author     xix
Introduction     xxi
Case Study: How Lean Failed     1
Gung Ho!     2
Lean Training     2
The First Kaizen Event     5
Struggling with Change     9
Raising the Bar: 5S Implementation     11
Improving Work Instructions     12
Lack of Accountability     13
The Second Kaizen Event     14
Giving Up on Lean     17
End of the Journey     19
The Change Commitment     21
The Three Main Drivers of Product Success     22
Cost     23
Quality     24
Delivery     25
The Big Picture     26
Owners     27
Employees     27
Suppliers     28
The Strategic Purpose     28
Productivity     29
Quality     30
Inventory and WIP     31
Floor Space Use     32
Throughput Time     33
Creating Your Strategic Purpose     34
Estimated Annual Improvement to the Metrics     34
Productivity     35
Quality     35
Inventory and Work in Process     36
Floor Space     37
Throughput Time     38
Departmental Responsibilities     38
Purchasing     39
Engineering     39
Sales and Marketing     40
Production Control     40
Maintenance     41
Chapter Wrap-Up     41
The Lean Infrastructure: Kaizen     43
Creating the Company Kaizen Program     44
Kaizen Champion     44
Kaizen Events     46
Kaizen Event Selection     47
Kaizen Team Selection     48
Manufacturing or Industrial Engineer     48
Quality Engineer     48
Facilities and Maintenance Personnel     49
Materials Operator     49
Line Operators     49
Management     50
Kaizen Team Leader Selection     50
Kaizen Event Date and Length     51
Kaizen Team Goals and Expected Results     52
Kaizen Event Planning     52
Kaizen Event Budgeting     53
Kaizen Steering Committee     53
Kaizen Champion      54
General or Plant Manager     55
Engineering Manager     55
Manufacturing Manager     55
Human Resource Manager     56
Purchasing or Materials Manager     56
Maintenance or Facilities Manager     56
Kaizen Event Tracking and Scheduling     57
Tracking     57
Pre-event Items     57
Post-event Items     58
Scheduling     58
Kaizen Event Communication     59
Kaizen Event Tracking Sheet     60
Kaizen Newsletter     61
Communication Boards     62
Employee Suggestion Box     62
Monthly Kaizen Meeting     63
Open Action Items     64
Past Kaizen Event Results and Lessons Learned     64
Upcoming Kaizen Events     64
Getting Started     65
Schedule a Meeting with Upper and Middle Management     65
Schedule and Conduct the First Kaizen Meeting     66
Create the Kaizen Event Tracking Sheet     66
Your First Kaizen Event     67
Planning     67
Selecting the Area     68
Selecting the Team Leader     68
Selecting Team Members     68
Week of the Kaizen Event     69
Day 1     69
Days 2 and 3     69
Last Day     70
Chapter Wrap-Up     70
Early Stumbling Blocks     71
5S and the Visual Workplace     72
Mistakes in Straightening     72
Mistakes in Sustaining     76
5S Audits     77
5S Tracking Sheet     79
Time and Motion Studies     79
Use a Stopwatch     80
Document the Work from Start to Finish     81
Collect the Work Content First     82
Waste Removal     83
High-Priority Waste     84
Medium-Priority Waste     85
Low-Priority Waste     86
Quality at the Source     87
Workstation Design     89
Lines versus Work Cells     89
Physical Flow     90
Conveyor Belts     91
Conveyor Rollers     91
Lift Tables     92
Workbenches     92
Mobile Lines     93
Material Presentation     93
Tool Presentation     94
Operator Fatigue and Safety      95
Painting and Lighting     95
Documentation     96
Chapter Wrap-Up     96
Operator and Supervisor Involvement     97
Standard Work     98
Following the Work Content     100
Using Single Piece Flow and Controlled Batches     102
Staying in the Workstation     104
Maintaining Communication     105
Working within Effective Hours     107
How to Get Them Involved     108
Using the Kaizen Suggestion Box     108
Kaizen Steering Committee Floor Representatives     109
Involving Operators in Data Collection     110
Lean Manufacturing Training     111
Chapter Wrap-Up     112
Lean Training Programs     113
Training Programs for New Employees     113
Company Product Overview     114
Quality Overview     115
Introduction to Lean Manufacturing     116
The Seven Deadly Wastes     116
5S and the Visual Workplace     118
Standard Work     118
Effective Hours     119
Kaizen     120
Mock Line Training     120
Cross-Training Program      121
Levels of Progression     122
Novice     122
Certified     123
Trainer     124
Progression of Temporary Workers     124
Cross-Training Matrix     125
Training Managers and Engineers     127
Managers     128
Engineers     128
Chapter Wrap-Up     129
Lean Manufacturing as a Growth Creator     131
Lean Goals     132
Pay-for-Skill Program     133
Number of Certifications     134
Years of Experience     134
Attendance     134
Kaizen and Kaizen Event Participation     135
Quality Errors     137
Providing Incentives for Good Ideas     139
Chapter Wrap-Up     140
Lean Leadership Made Simple     141
Poor Leadership Traits     143
The Master Delegator     143
The Yes/No Manager     144
The Crisis Junkie     144
The Poor Decision Maker     144
The Personal Boss     145
A More Congenial Leadership     145
Acknowledge and Involve Your Staff     145
Provide an Environment in Which People Can Be Successful     146
Do Not Humiliate Anyone Who Works for You     146
Create an Environment Where Mistakes Are OK     146
Remember Personal Details     146
Don't Hide behind Your Position     147
Be Approachable     147
Admit Your Mistakes     147
Listen in a Way That Encourages Employees to Talk to You     147
Be Clear in Your Requests     148
Stand behind Your People     148
Be a Good Communicator     148
Effective Lean Leadership     149
Ten Signs of Incompetent Lean Leaders     151
Five Lean Leadership Rules for Success     153
Chapter Wrap-Up     155
Quick Reference     157
The Seven Deadly Wastes     157
Key Elements of a Company Kaizen Program     158
Supplemental Material     159
5S Audit Form     159
5S Tracking Sheet     159
Time Study Sheet     159
Glossary     163
Index     167