This plain language guide to the lean production system is written for practitioners by a practicing engineer,
offering an insider's view of lean manufacturing as a whole and its components, its origins and underlying principles,
its goals, and the activities that support involvement, such as kaizen circles and suggestion systems. Toyota's
lean manufacturing system is used as an ongoing example. Dennis is an engineer who has worked with lean experts
in Japan and North America.
Table of Contents
1. The Birth of Lean Production
Craft Production
The Mass Production System
The Growing Dysfunction
The Birth of Lean Production
The Historic Bargain
A Virtue of Necessity
Completing the Lean Revolution at Toyota
Summary
2. The Lean Production System
Why Lean Production?
Systems and Systems Thinking
Basic Image of Lean Production
Customer Focus
Muda
Summary
3. Stability
Standards in the Lean System
The 5S System
Total Productive Maintenance
Summary
4. Standardized Work
Methods Engineering versus Lean Thinking
What Do We Have to Manage?
Why Standardized Work?
The Elements of Standardized Work
Charts Used to Define Standardized Work
Manpower Reduction
Overall Efficiency versus Individual Efficiency
Standardized Work and Kaizen
Common Layouts
Summary
5. Just-In-Time
Why JIT?
Basic Principles of JIT
The JIT System
Kanban
The Six Kanban Rules
Expanded Role of Conveyance
Production Leveling
Three Types of Pull Systems
Value Stream Mapping
Summary
6. Jidoka
Development of the Jidoka Concept
Why Jidoka?
Poka-yoke
Inspection Systems and Zone Control
Using Poka-yokes
Implementing Jidoka
Summary
7. Involvement--The Wind That Fills the Sail
Why Involvement?
The Terrible Waste of Humanity
Activities Supporting Involvement
Kaizen Circle Activity
Practical Kaizen Training
Suggestion Programs
Summary
8. Hoshin Planning
What Is Planning?
Why Plan?
Problems with Planning
Hoshin Planning
Hoshin Planning System
The Four Phases of Hoshin Planning
Summary
9. The Culture of Lean Production
What Is Lean Culture?
How Does Lean Culture Feel?
Summary
