The Hitchhiker's Guide to Lean
Encyclopedia

Summary

This book covers lean manufacturing
Lean manufacturing
Lean manufacturing, lean enterprise, or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination...

 principles and thinking, lean leadership moves, the road map for lean transformation, common pitfalls of lean journeys, building an operating system, lean accounting
Lean accounting
The purpose of Lean Accounting is to support the lean enterprise as a business strategy. It seeks to move from traditional accounting methods to a system that measures and motivates excellent business practices in the lean enterprise.- Introduction :...

, lean material management, lean in service organizations, and how individuals can apply lean to improve themselves. It concludes with interviews of lean practitioners at Chrysler
Chrysler
Chrysler Group LLC is a multinational automaker headquartered in Auburn Hills, Michigan, USA. Chrysler was first organized as the Chrysler Corporation in 1925....

, Ross Controls, DTE Energy
DTE Energy
DTE Energy Co. is a Detroit, Michigan-based utility incorporated in 1995 involved in the development and management of energy-related businesses and services nationwide....

, RSR Corporation, and Nemak.

Table of Contents

Acknowledgments vii
Foreword ix
Introduction xiii

1 THINK FIRST: FIVE PRINCIPLES OF LEAN
Principle One: Directly Observe Work as Activities, Connections, and Flows
Principle Two: Systematic Waste Elimination
Principle Three: Establish High Agreement of What and How
Principle Four: Systematic Problem Solving
Principle Five: Create a Learning Organization

2 PEOPLE NEED LEADERSHIP, NOT MANAGEMENT: Five LEADERSHIP MOVES FOR LEAN
Leadership Move One: Leaders Must be Teachers
Leadership Move Two: Build Tension, Not Stress
Leadership Move Three: Eliminate Fear and Comfort
Leadership Move Four: Lead through Visible
Participation, Not Proclamation
Leadership Move Five: Build Lean into Personal Practice


3 LEARNING CAN BE EXPENSIVE: FIVE COMMON LEAN PITFALLS (AND HOW TO AVOID THEM)
Pitfall One: Believing Lean is Only About Manufacturing
Pitfall Two: The Lean Department should not be Leading Lean
Pitfall Three: Activity should not be Confused with Productivity
Pitfall Four: Event Lean Prevents a Company from Becoming Genuinely Lean
Pitfall Five: Tortoise Lean will Beat Hare Lean


4 A THOUSAND-STEP JOURNEY: FIVE PHASES OF THE TRANSFORMATION ROADMAP
What Lean is—and is Not
Lean Transformation Evaluation Criteria
The Transformation Roadmap


5 PULLING IT ALL TOGETHER: FIVE DIMENSIONS OF AN OPERATING SYSTEM
What is an Operating System?
An Operating System Aligns “How” with “What”
Benefits of an Operating System
The Operating System Framework
Building the Operating System Framework
A Tale of Two Operating Systems


6 RELEARNING TO COUNT: FIVE LEAN ACCOUNTING PRINCIPLES
A Brief History Lesson
Lean Accounting Principle One: Accounting is a Process, Not Just a Profession
Lean Accounting Principle Two: Go Beyond the Numbers
Lean Accounting Principle Three: Transition from Cost Cop to Coach
Lean Accounting Principle Four: The First Filter is Value and the Customer
Lean Accounting Principle Five: Make Data Accessible for the Customer
Next Steps


7 MOVE IT OR LOSE IT: FIVE KEYS TO LEAN MATERIAL MANAGEMENT
Concept One: Information Blindness
Concept Two: Eliminate the White Space
Concept Three: Right-size Everything—Right Tool, Right Place, Right Time, and Right Cost
Concept Four: Moving One Inch is Still a Transport
Concept Five: Eliminate Functional Tunnel Vision


8 SERVICE ON A SILVER PLATTER: FIVE FACTORS FOR LEAN SERVICE
What are the Operational Objectives?
How is Lean Service Different from Manufacturing?
Five Factors for Lean Service
Case Studies


9 THE TRANSFORMATION OF ONE: FIVE PRACTICES FOR PERSONAL LEAN
Practice One: Always Work for the Customer
Practice Two: Problem Solving at a Relationship Level
Practice Three: Personal Learning Through
Plan/Do/Check/Act
Practice Four: Master What You can Control
Practice Five: See More with Your Own Eyes


10 CONVERSATIONS FROM THE ROAD
Robert Finn, RSR Corporation
Shawn Patterson, DTE Energy
DTE Energy
DTE Energy Co. is a Detroit, Michigan-based utility incorporated in 1995 involved in the development and management of energy-related businesses and services nationwide....

Dennis Pawley, Chrysler Corporation
Robert Smillie, Nemak Corporation
John Smith, Ross Controls
Index
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