Relentless Improvement: True Stories of Lean Transformations
Features
- Supplies a feel for the environments in which Lean transformations occur
- Provides a crucial implementation guide geared to functions on the operational level
- Presents real-life stories based on the author’s experiences
- Reflects practical manufacturing situations
Summary
Tracing the author’s decades-long continuous improvement journey, Relentless Improvement: True Stories of Lean Transformations walks readers through vivid shop floor experiences to convey a genuine feel for the environments in which Lean Six Sigma transformations occur. Recounting numerous Lean Six Sigma transformations, it illustrates the spectrum of successful operational tactics.
The story starts just outside Detroit, Michigan in the 1970s when the auto industry was booming, and most people in the area worked in the car factories, or in one of the component factories that supplied the Big Three. The complexity and detail of the projects grow chapter by chapter. The book begins by explaining how to manage Lean basics such as applying 5S, shortening product cycle times, and creating standard work. It then progresses to factory Lean Six Sigma transformations. Providing implementation guidance geared to functions on the operational level, the book:
- Presents stories based on the author’s interactions with company leaders and shop-floor employees in the midst of great change
- Illustrates real-world plant politics and manufacturing situations using compelling stories
- Highlights valuable lessons learned at the end of each chapter
Using an engaging story format, the book recounts the author’s career experiences to provide you with a real-world understanding of how to use Lean tools. The stories in the book illustrate everything from standard work and takt time to Kaizen events and Total Productive Maintenance. The text also includes accounts of "front end" or administrative processes such as product development and materials handling.
Table of Contents
A Manufacturing Family
Lessons Learned
My First Factory
Lessons Learned
Maybe Not Lean, But Lean Things
Do It Right the First Time
Product Development
Problem Solving
Takt Time
Standard Work
Lessons Learned
My First Process Improvement Project
Leadership Nirvana
Lessons Learned
Process Improvement Project #2
The New Owners Are at the Gate
Lessons Learned
My Lean Journey Begins
Water Spiders
The Building Is on Fire
Hazardous Spill
Lessons Learned
Outboard Marine Corporation — Marine Power
Marine Power Product Group Purchasing
Getting to Know the Gemba: The Product and the People
OMC–Burnsville
OMC – Calhoun
Lessons Learned
Jet Skis
Lesson Learned
Cylinder Sleeves
Lessons Learned
More Standard Work
Lessons Learned
Japan
Are You Sure He Is Not Mad at Me?
Closing Out the Audit
Mouth Test
Lessons Learned
Multi-Plant Inventory Reduction
Lesson Learned
Bearing Shortage
Lesson Learned
Stickle Bricks: One-Piece Flow
Affinity Diagram
Lesson Learned
The War Room
Lesson Learned
The Project Continues
Design for Manufacture and Assembly
Proven Technology versus High-Tech
Lesson Learned
Competitive Product Comparison Project: Boston
Consulting Group
Lesson Learned
Lean Transformation # 1
The "Incentive" System
Quality at the End of the Line
The Aft Cabin
Rate versus Quality
Let’s Summarize
The Loop
The Transformation Begins
5S
Quality: Stabilizing the Processes
Quarter Drills: Production Status Boards
Manufacturing Engineers/Process Improvement Technicians
Lean Training
Boot Stripe Rework Reduction: Defects, Non-Value-Added Rework
Lesson Learned
Where to Start
Grinding and Flipping Fiberglass Decks: Waste, Rework, Transportation, Motion
Fiberglass Small Parts
Components Plant
Let’s Get Lean
Lean Transformation #2
Process Improvement at Wellcraft
Lamination Process Improvement
Mold Care Project
Assembly Process Improvement
Implement 5S
Quality Process
Lean Six Sigma Cost Reduction Projects
Product Development
Lesson Learned
Improve Design Engineering Process
Improve Materials Management Process
Lean Transformation Strategies
Elements of a Successful Lean transformation
Develop a Lean Roadmap
Get a Lean Leader
Establish a Lean Steering Committee
Establish a Lean Resource Plan
Establish a Lean Team in the Company
Establish and Communicate the Lean Vision for the Company
Develop the Roll-Out Plan
Implement the Plan
Implement Relentless Improvement
Map and Improve Support Processes
Move to Advanced Lean
Implement the Roll-Out Plan
General Training: Lean Values, Overview
5S Implementation
Map and Improve Value Streams
Implement Lean Metrics and Visual Management
Total Productive Maintenance (TPM)
Align Product Development/New Product Launch with Lean Principles
Deploy and Sustain Relentless Improvement Activities
Map and Improve Support Processes
Kaizen Events
Move to Advanced Lean
Miscellaneous Topics
Various
Organizational Politics Leadership
How to Conduct a Process Mapping Event
DAY 1
DAY 2
DAY 3
Index