How To Implement Lean Manufacturing | Date: 28 April 2011, 08:02
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How To Implement Lean Manufacturing
By Lonnie Wilson
* Publisher: McGraw-Hill Professional
* Number Of Pages: 336
* Publication Date: 2009-08-11
* ISBN-10 / ASIN: 0071625070
* ISBN-13 / EAN: 9780071625074
Product Description:
A Practical, Hands-on Guide to Lean Manufacturing
This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made.
How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to:
* Rigorously test and retest the state of your "leanness" with unique evaluators
* Develop and deploy plant-wide strategies and goals
* Improve speed and quality and dramatically reduce costs
* Reduce variation in the manufacturing system in order to reduce inventory
* Reduce lead times to enable improved responsiveness and flexibility
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Synchronize production and supply to the customer
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Create flow and establish pull-demand systems
* Perform system-wide and specific value-stream evaluations
* Generate a comprehensive list of highly focused Kaizen activities
* Sustain process gains
* Manage constraints and reduce bottlenecks
* Implement cellular manufacturing
Summary: Comprehensive, Insightful, and Very Practical Guide to Lean
Rating: 5
I took this book on a week's vacation thinking that I would breeze through yet another book on Lean. I was very mistaken. I found myself again and again needing to slow down, think, and really consider what Lonnie Wilson is saying. There's a clarity and focus to understanding lean, and from many different perspectives, that can only come from years of experience and from deep thinking.
I'm impressed with the breadth of treatment here: TPS as a quantity control system, the bedrock assumptions of quality control and process stability, the interrelationships with 6 Sigma and TOC, the cultural underpinnings and dynamics of cultural change, the practical tools, dealing with the real world of constraints and variation, the assessment approach along with the prescriptions, the refreshing focus on early and quantifiable gains. And along the way, detailed and insightful case studies really help to illustrate. But it's deep as well as wide: from the rigor of the mathematical calculations to the subtleties of managing cultural change. I found the idea that problem creation is a key role of management (p. 161) to be remarkably insightful.
I've been deeply immersed in lean for the past 10 years, yet this book was completely refreshing and one that I will go back to again and again. Highly recommended whether you are just starting in or have been doing lean for years.
Summary: Finally, a down to earth Lean book that tells it like it is!
Rating: 5
As a Director of Quality for seven years, and a Quality professional for 18 years, this is the most helpful, easy to read book I have ever read on implementation of lean. I have read works of Ohno, and books by others that simply regurgitate what they think Ohno or Shingo meant...finally, this is a book that is written by a lean guru in his own right, Lonnie Wilson, but written more as if you're actually in training, by a trainer that really knows the shop floor and has worked with shop floor people and real managers with real challenges throughout the world. I literally found myself on the shop floor, "listening" to Lonnie Wilson as if he was standing next to me telling me what to do. The book is motivating and feels conversational, as if your lean mentor is just having a conversation with you, teaching you and showing you how to implement lean-making the key points clear. It becomes clear that, like most things, there is no silver bullet or substitute for hard work, but... substantial gains can be made, and much can be made short term. Although there's no substitute for actually having your own lean mentor, this book is as close as I've seen and- the investment is certainly insignificant relative to what you will get out of it. I highly recommend it!
Summary: Outstanding Practical Guide to Lean Manufacturing!
Rating: 5
If you have read "LEAN THINKING" by James P Womack and Daniel T. Jones, you may have been left wondering what Lean Manufacturing and the Toyota Production System was all about. It may have seemed mysterious and not well defined. Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING" is a guidebook to Lean Manufacturing that will take the mystery out of process for you. It is a practical HOW-TO guide that can be used by plant managers, executives, quality managers and production personnel to implement the Lean Systems within their facilities.
This book not only addresses the strategy on how to implement Lean Manufacturing but also addresses cultural change necessary for a successful transformation. In the end you have to sustain the gain and the book tells you what is necessary.
What makes this book standout from other Lean texts is that the book itself is written in a Lean style of writing. Lonnie uses "Points of Clarity" to highlight important concepts within the book. Additionally he uses hundreds of visual graphics and tables that draw the reader's attention. Visual clues and organization is a key concept in Lean. I don't think you can turn two or more pages without being grabbed by a new visual to help make a point in the book.
I was impressed with the level of practical detail. Need to calculate OEE or the proper KANBAN size? Does Value Stream Mapping have you confused? The book provides the formula's necessary. It places these concepts in context to the big picture of efficiency, lead-time or cycle-time reduction. The book is filled with personal examples from Lonnie Wilson's career leading transformation efforts. Case studies are also given to drive home and follow the complete process of a successful Lean project and some that are not so successful.
This is a book I would personally recommend to anyone getting ready to attend a Lean training workshop. Read this book first and you will be prepared for your class. As a university instructor, I like to tell my students, "The answer is in the book". I think you will find many insightful answers about Lean in Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING".
Summary: A how to manual to Lean Manufacturing in the real world
Rating: 5
The Japanese word "sensei" is usually translated into English as "teacher" but the literal translation, and possible better translation for this purpose, is "one that has gone before".
Lonnie Wilson's practical and pragmatic new book "How To Implement Lean Manufacturing" shows why Lonnie deserves the title "sensei". Lonnie shows us the way, and the potholes, because he has gone this way before, many times.
Mixing lean, theory of constraints, and six sigma (aka variation reduction), Lonnie shows how to move companies forward towards a better business model and greater profits. His writing style is personal and direct which makes the book easy to read in addition to causing deep thought about our own experience, leadership, and business situation. Lonnie does not lecture on about theory but shows practical applications and examples of how to use the Toyota Production System and Lean Manufacturing in our companies here and now.
After reading this book cover-to-cover I will keep it handy for reference and to have colleages read sections and discuss. I think everyone that is engaged in impleme
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