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