9780273770503

Use lean management to improve efficiency, increase customer value, cut waste, and make the most of limited resources! In today's economic climate, lean techniques are more valuable than ever: this book will help you understand and apply them. Covers all of today's most valuable lean tools, showing how to choose amongst them and integrate them into your organization. Includes expert coverage of lean culture, the technical and 'people' side of lean, and building a 'Lean Roadmap to Transformation.FT Guide to Lean will show you how to use lean management techniques to drive greater efficiency and increase customer value at the same time. Leading lean consultant Andy Brophy introduces each leading tool for implementing lean, helping decision-makers and practitioners decide which tools offer the greatest opportunities, and then successfully integrate them throughout their organizations. Using practical examples drawn from his extensive in-thetrenches experience, Brophy fully explains the principles of lean and lean management, and guides readers through crafting lean strategies and roadmaps that reflect their unique environment and challenges. Topics covered include: Lean concepts, the 'five principles of lean,' Hoshin Kanri, and value stream mapping. 5S Workplace Organization, A3 problem solving, Kaizen, Idea Management Systems, Quick Changeover, Kanban, and Flow Practices. Developing lean culture: accountability processes, expectation setting, recognition, coaching, delegation, constructive feedback, and escalation. Successfully managing both the technical and human issues associated with sustaining lean, from tracking and metrics to engagement and risk taking.

Andy Brophy is a lean & innovation facilitator who has been working in the lean field for the past twelve years in domains including manufacturing, hospital, software development, hospitality, food and financial services. He is Director of the consultancy business Lean 2 Innovative Thinking. Andy holds a 1st Class MSc in Lean Operations and is a Six Sigma Black Belt. In 2010 he published a co-authored book with John Bicheno called Innovative Lean.

http://www.lean2innovativethinking.com/

Table of Contents

Acknowledgements

Introduction

Part I: Getting started: Lean orientation and diagnostic phase

Chapter 1 Lean management

What is Lean?

Why Lean?

Brief history of Lean

Lean today

True North Lean

The five principles

The Lean operating system

First Pillar: Continuous improvement

Second Pillar: Respect for People

Hidden waste is robbing our profits

Muda

Muri

Mura

Chapter 2 Hoshin Kanri strategy deployment

Introduction

The Hoshin process

1. Reflection on the previous year’s performance

1.2 Review of the organisations vision, mission, and values

1.3 Objectives for the forthcoming year

1.4 Alignment building and action plans

1.5 X-matrix development

1.6 Monthly evaluation

1.7 Annual evaluation

Review

Chapter 3 Value stream mapping

Introduction

What flows in value stream maps?

Value stream mapping categories

Value stream mapping stages

1. Team formation

2. Draw the current state value stream map

3. Create the ideal state value stream map

4. Develop the future state value stream map

5. Develop the improvement plan

Case Study: Outpatients orthopaedic clinic

Global background

Outpatient’s clinic overview

Current state value stream map baseline discussion

Clinic ideal state value stream map discussion

Clinic future state value stream map discussion

Box score discussion

Review

Part II: Lean transformation practices

Chapter 4 Lean methods and tools (part I)

Section 1: 5S workplace organisation

Introduction

Waste (symptom) and 5S countermeasure

How to apply 5S workplace organisation

Sort

Set-in-Order

Shine

Standardise

Sustain

5S review

Section 2: Visual management

Why use visual management

Levels of visual management

Visual management centre (VMC)

Operational tracking at the gemba

Visual management review

Chapter 5 Lean methods and tools (part II)

Section 1: A3 problem solving

Introduction

Why A3

A3 document

1. Cause and effect diagram

2. Pareto chart

3. Process map

4. Tally sheet

5. Scatter plot

6. Run chart

7. Histogram

Types of A3

Categories of problems

A3 review

Section 2: Standard work

Introduction

Standard work and job classifications

Improving standard work

Bringing standard work to life

Job breakdown sheet

Standard work review

Chapter 6 Lean methods and tools (part III)

Section1: Idea management system

Introduction

Documenting ideas is crucial

Idea metrics

Reward and recognition

Idea process flow

Idea management system review

Section 2: Kaizen events

Introduction

Kaizen stages

Pre-event preparation

Event workshop

Confirmation phase

Kaizen review

Chapter 7 Lean methods and tools (part IV)

Section 1: Quick changeover

Introduction

Why quick changeover

SMED methodology

Quick changeover review

Section 2: Total productive maintenance

Introduction

Why TPM?

Application of TPM

TPM improvement plan

TPM review

Chapter 8 Lean methods and tools (part V)

Section 1: Kanban

Introduction

Why kanban

Types of kanban

Kanban sizing calculation example

Culture and people implications

Kanban rules

Supplier kanban in a hospital setting

Kanban in a hospital setting

Kanban review

Section 2: Poke yoke

Introduction

Mistake proofing classifications

Mistake proofing routine

Poke yoke review

Chapter 9 Lean methods and tools (part VI)

Flow practices

Introduction

River and rocks analogy

Batch size implications for flow

A word on inventory

The problem with traditional production scheduling using Materials Requirement Planning (MRP)

Preconditions for flow

Family identification

Map the value stream

Identify bottlenecks and variation

Cellular flow

Human implications for flow

Flow practices review

Part III: Leading the Lean transformation

Chapter 10 Developing the Lean culture

Introduction

Cathedral model

Model foundation

Accountability process

Set expectations

Recognition

True coaching and delegation

Double diamond coaching model

Constructive feedback

Escalation

Quantity and quality

Review

Acknowledgement

Chapter 11 The technical side of sustaining Lean

Introduction

Systems thinking

Hoshin Kanri strategy deployment

Leadership

Sustaining Lean through problem solving

Lean daily management system

Training within industry (TWI)

Metrics

Review

Chapter 12 The people side of sustaining Lean

Introduction

Leadership

Engaging people in Lean

Oh, if only we had the luxury of time for improvement work!

Communication

Middle management

A propensity for risk taking

A rising tide should lift all boats

Review

Chapter 13 Putting it all together: The Lean Roadmap to Transformation

Introduction

Generic roadmap

1. Understand value through the eyes of your customers

2. Articulate the business case for transformation

3. Lean assessment

4. Value stream mapping

5. Build leadership commitment and set expectations

6. Hoshin Kanri strategy deployment

7. Management of change plan

8. Pilot Lean model area and spread plan

9. Build the Lean knowledge

10. Lean culture

11. Sustaining Lean

12. Hansei

Review

References and further reading

Glossary

Appendix

Index

What is included with this book?

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FT Guide to Lean How to streamline your organisation, engage employees and create a competitive edge

FT Guide to Lean How to streamline your organisation, engage employees and create a competitive edge

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Summary

Author Biography

Table of Contents

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