All About Work Standards is a practical and utilitarian guide to creating, implementing, maintaining, and improving work standards, the key to continuous improvement. It includes examples from a broad range of industries, and explains the difference between work standards and Toyota Standard Work. The book also explores Leader Standard Work, including its purpose, potential, and limitations. This hands-on resource is essential for practitioners, students, and researchers in lean manufacturing.
Praise for All About Pull ProductionStandards are, in my opinion, the most important foundation of Lean and one which is often underrated and given less attention by manufacturing professionals. This is one of the main reasons why implementations of lean manufacturing often fail to deliver their full potential or at all. The discipline of setting and maintaining work standards and standard work is absolutely essential to lean manufacturing. Professor Roser has produced another masterpiece on lean which takes the reader through the different steps of writing, implementing, and improving standards, and with the added bonus of details on related topics such as OEE, TPS problem solving, and line balancing. It is full of practical examples and invaluable advice for the reader, and a must-have for all lean manufacturing practitioners. A superb addition to lean literature. - Cheong Tsang, Bosch Plant Manager (Retired)
Prof. Dr. Roser is an irreplaceable professional in teaching and studying production management systems. He has long experience and much knowledge as a practitioner and a consultant in lean management all over the world. Today he is the most active figure outside Japan in research on the Toyota Production System. Readers will definitely obtain a lot of valuable insights and new ideas from his book on work standards which are often referred to Toyota. - Dr. Masaru Nakano, Professor, Keio University; Former Toyota Manager
Christoph Roser has assembled a veritable encyclopedia in All About Work Standards, featuring standard work and work standard examples from a wide range of industries worldwide. - Mark Warren, Manufacturing Engineer and Production Historian
Christoph has done the operations world a huge service by writing a comprehensive book on a topic of fundamental importance but one that has been inadequately discussed until now. Despite being a foundation stone in the Toyota house, manufacturing standards have long been a source of confusion even amongst lean practitioners. With his customary clarity, Christoph sets out history, types, guidelines, implementation, and pitfalls. How standards relate to OEE and problem solving are the cherry on the top. Superb! - Dr. John Bicheno, Emeritus Professor of Lean Enterprise, University of Buckingham
Coordination of work is the key ingredient for any business success. The better the coordination, the less process wastes. For decades it has been known that there are three ways to realize coordination: standardization, planning, and mutual adjustment. It is also well known that standardization is the most effective and efficient. Still, most literature focuses on better planning and control instead of trying to standardize first. Christoph Roser redresses the balance, which provides a major input for any operating manager. - Matthias Thürer, Professor for Factory Planning and Intralogistics, University of Technology Chemnitz
Lean Leader Formula - People, or How to Grow in Manufacturing faster than 90%, provides a comprehensive guide for aspiring and current manufacturing leaders (and to-be leaders) on how to accelerate their growth within the industry.
The author, Hayk, shares personal insights and strategies based on his 17 years of experience and those of successful leaders in the field.
The book explores various aspects of leadership development, including team building, motivation, effective communication, managing emotions, and conflict resolution.
The author also highlights the importance of understanding company needs, knowing your team, and identifying leadership styles to create a tailored approach.
The book emphasizes the role of trust, open communication, and continuous feedback as crucial elements for building a successful and fulfilling career in manufacturing (and not only).
From the early twentieth century until the 1960s, Maine led the nation in paper production. The state could have earned a reputation as the Detroit of paper production, however, the industry eventually slid toward failure. What happened? Shredding Paper unwraps the changing US political economy since 1960, uncovers how the paper industry defined and interacted with labor relations, and peels away the layers of history that encompassed the rise and fall of Maine's mighty paper industry.
Michael G. Hillard deconstructs the paper industry's unusual technological and economic histories. For a century, the story of the nation's most widely read glossy magazines and card stock was one of capitalism, work, accommodation, and struggle. Local paper companies in Maine dominated the political landscape, controlling economic, workplace, land use, and water use policies. Hillard examines the many contributing factors surrounding how Maine became a paper powerhouse and then shows how it lost that position to changing times and foreign interests.
Through a retelling of labor relations and worker experiences from the late nineteenth century up until the late 1990s, Hillard highlights how national conglomerates began absorbing family-owned companies over time, which were subject to Wall Street demands for greater short-term profits after 1980. This new political economy impacted the economy of the entire state and destroyed Maine's once-vaunted paper industry. Shredding Paper truthfully and transparently tells the great and grim story of blue-collar workers and their families and analyzes how paper workers formulated a folk version of capitalism's history in their industry. Ultimately, Hillard offers a telling example of the demise of big industry in the United States.
The toy industry is one of the most consistently misunderstood sectors of American business, comprising a wide range of businesses under one banner-entertainment, commodities, fashion, and licensing-that each behave differently. Unlike other industries, more than 40 percent of products are new every year, and success often depends on the whims of a child.
Currently about $22 billion per year at wholesale for traditional toys, the United States toy industry has remained relatively constant since the 1990s, with a short-term boom in 2020 and 2021 in response to a global pandemic.
This edition has been updated to reflect these and other dynamic changes in recent years, including the impacts of shifts in marketing, technology, consumption, and retailing. It offers an introduction to the structure, practices, and market forces that impact the toy industry, including a short history, a description of the current market landscape, product trends, emerging opportunities and threats and expectations for the future.
The primary focus is the U.S. toy industry, but one cannot ignore the global scope of the business, particularly with respect to manufacturing and opportunities for growth in emerging markets. It is intended to provide a foundation for understanding the diverse and dynamic nature of the toy industry and many things that make it unique and to introduce this fast-paced, always changing and fiercely competitive business where success is often more an art than a science.Winner of a 2009 Shingo Research and Professional Publication Prize.
Notably flexible and brief, the A3 report has proven to be a key tool In Toyota's successful move toward organizational efficiency, effectiveness, and improvement, especially within its engineering and R&D organizations. The power of the A3 report, however, derives not from the report itself, but rather from the development of the culture and mindset required for the implementation of the A3 system.In Understanding A3 Thinking, the authors first show that the A3 report is an effective tool when it is implemented in conjunction with a PDCA-based management philosophy. Toyota views A3 Reports as just one piece in their PDCA management approach. Second, the authors show that the process leading to the development and management of A3 reports is at least as important as the reports themselves, because of the deep learning and professional development that occurs in the process. And finally, the authors provide a number of examples as well as some very practical advice on how to write and review A3 reports.
The book effectively demystifies AI in manufacturing, tackling a key barrier: understanding. Its straightforward and humble tone makes for an enlightening read, perfect for a few hours of deep diving without feeling overwhelmed.
- Manufacturing Expert
Markus's insightful approach makes understanding AI's impact in manufacturing approachable. This book is a valuable guide for those looking to grasp the essentials of Industry 4.0.
- Professional in Manufacturing Operations
Markus's book presents a clear and engaging exploration of AI in manufacturing. It's a thoughtful read that has encouraged me to further expand my knowledge
- Digital Transformation Manager
The flywheel analogy used by Markus elegantly conveys the ongoing impact of AI in the manufacturing sector. As a General Manager, I found this perspective especially enlightening for comprehending the cycle of continuous innovation in our field.
- General Manager, Manufacturing Industry
In Artificial Intelligence WILL Revolutionize Manufacturing, Markus offers a concise yet profound exploration of how Artificial Intelligence is set to transform the manufacturing industry. Drawing from his own experiences and deep understanding of AI, Markus effectively demystifies the concept of Industry 4.0. The book focuses on the Industry 4.0 Flywheel, a model demonstrating how continuous improvement and innovation can be achieved through AI and Machine Learning. Markus provides actionable steps for manufacturers to integrate AI into their processes, emphasizing the technology's transformative potential. This guide is not just informative but a compelling invitation to industry professionals to embrace AI and drive a revolution in manufacturing.
American manufacturing is on life support--at least, that's what most people think. The exodus of jobs to China and other foreign markets is irreversible, and anything that is built here requires specialized skills the average worker couldn't hope to gain. Not so, says Dan DiMicco, chairman and former CEO of Nucor, America's largest steel company. He not only revived a major US manufacturing firm during a recession, but helped galvanize the flagging domestic steel industry when many of his competitors were in bankruptcy or headed overseas. In American Made, he takes to task the politicians, academics, and political pundits who, he contends, are exacerbating fears and avoiding simple solutions for the sake of nothing more than their own careers, and contrasts them with the postwar leaders who rebuilt Europe and Japan, put a man on the moon, and kept communism at bay. We need leaders of such resolve today, he argues, who can tackle a broken job-creation engine by restoring manufacturing to its central role in the U.S. economy--and cease creating fictitious service businesses where jobs evaporate after a year or two, as in a Ponzi scheme.
With his trademark bluntness, DiMicco tackles the false promise of green jobs and the hidden costs of outsourcing. Along the way, he shares the lessons he's learned about good leadership, crisis management, and the true meaning of innovation, and maps the road back to robust economic growth, middle-class prosperity, and American competitiveness.Although you cannot learn about Lean without 'Gemba' experience, games allow the next best thing by fostering a richness of understanding, discussion, participation, and decision making that are essential elements for successful Lean implementation. This book is the second edition of a compendium of participative games to be used by trainers and facilitators to assist them in implementing Lean, Six Sigma and Operational Excellence programs. The book is relevant to both manufacturing and service. A total of 47 games are included, each with full description, player and instructor notes, and game sheets. No special equipment is required other than dice and household items such as scissors. The games range from basic to advanced. Several of the games are arranged in sets, allowing greater in depth exploration of issues. The appendix contains game sheets that are copied and distributed to players. There are approximately 40% more games in this edition, and many of the games in the first edition have been revised and improved.
NOTE: THIS BOOK IS FOR EXPERIENCED LEAN TRAINERS ONLY. THEY WILL HAVE A KNOWLEDGE OF LEAN CONCEPTS AND TOOLS. ONE COPY PER SITE IS ALL THAT IS REQUIRED. DO NOT BUY THE BOOK IF YOU ARE LOOKING FOR GENERAL LEAN INSTRUCTION.
How one tenacious company found the drive to succeed--on a global scale
In the early 1980s, Caterpillar, Inc. lost one milliondollars per day for three consecutive years. Its continuing existence came into question. Today, CAT is the world's most profitable manufacturer of construction and mining equipment and large engines. The now legendaryglobal company made numerous well-calculated, though risky decisions for three consecutive decades--in the process scaling to heights unimaginable to even the finest businessenterprises.
How did they do it? The Caterpillar Way.
Senior management at CAT facilitated the authors' one-year odyssey through the hallways and intriguing history of the construction industry giant. This inspiring book takes you behind the scenes with the CEOs, executive vice presidents, managers, dealers, customers, union bosses, and Wall Street analysts who were players in Caterpillar's drive to global dominance. You'll discover:
The Caterpillar Way provides essential managementlessons in powerful behind-the-scenes stories. You'll learn how the Caterpillar leaders responded quickly to changing markets, allocated capital efficiently throughout the firm, and nourished a cultish team spirit that wins.Innovative leaders make game-changing decisions.
If any company is built to last, it's Caterpillar, Inc. With its trademark yellow trucks, cranes, machinery and engines, this home-grown manufacturer has survived morethan its share of ups and downs to become the #1 industry leader of construction equipment in the world. The Caterpillar Way reveals, for the first time, the remarkable inside story, written with full access to the way CAT runs its business, from bottom to top.
They blaze their own trail. This is The Caterpillar Way.
PRAISE FOR THE CATERPILLAR WAY:
The Caterpillar Way is a very sophisticated analysis of one of the great organizational stories of the past 30 years. Bouchard and Koch delve into the details of leadership, risk, and culture that allowed this company to excel. From branding to comparative advantage, this is an extraordinary example of vision and execution. -- Sam Zell, Chairman, Equity Group Investments
The Caterpillar Way brings to life the progress a company can make by having a plan and sticking to it quarter by quarter and year over year. The company never stands still and has a keen focus on delivering high-quality products on time to its customers. They have been a great partner of ours for many years. -- Dave Cote, Chairman and CEO, Honeywell
There's no way you can't learn from The Caterpillar Way--a classic example of how to bring strategy, structure, and culture together to drive breakthrough results. -- David C. Nova k, Chairman and CEO, Yum! Brands Inc.
Mapping the Total Value Stream defines and elaborates on the concepts of value stream mapping (VSM) for both production and transactional processes. This book reshapes and extends the lessons originally put forward in a number of pioneering works including the popular, Value Stream Management for the Lean Office. It reinforces fundamental concepts and theoretical models with real-world applications and complete examples of the value stream mapping technique. To educate VSM mappers on the specific mechanics of the technique, the text provides in-depth explanations for commonly encountered situations.
The authors also provide a more complete perspective on the concept of availability. While they discuss availability of equipment in transactional processes, they extend the concept by elaborating on availability as it applies to employees. The calculation of process lead time for work queues is taken to an advanced level - not only is the calculation of this lead time explained, but the text also covers the very real possibility of having more work in the queue than available time.
While previous books have focused on only production process VSM or transactional process VSM, this work meets the real needs of both manufacturers and service sector organizations by dealing with both types. It goes beyond explaining each scenario, to teach readers what techniques are commonly applicable to both, and also explains areas of difference so that mappers will be able to readily adapt to whatever unique situations present themselves.
This revised and updated book explores the academics behind managing the complex service environment that is the Emergency Department (ED) by combining applied management science and practical experiences to create a model of how to improve operations. This book offers a presentation of Lean tools used in the ED along with basic and advanced flow principles. It then shows how these concepts are applied and why they work, supported by case studies in which Lean principles were used to transform an underperforming ED into a world-class operation. After reviewing best practices, the authors explain how to achieve excellence by discussing the elements of creating a culture of change.
Souls of Iron tells the remarkable story of a multi-generational family iron mining and manufacturing dynasty in Central Pennsylvania which began before the Revolutionary War and lasted until shortly after WWI. The story begins with the arrival in Philadelphia of a sixteen-year-old immigrant with two months worker wages in his pocket. By the time of his death in 1825 he was one of the wealthiest iron masters in Pennsylvania. Through the next four generations his descendants splintered into separate businesses all of which were purchased by Bethlehem Steel for tens of millions of dollars. The family weathered multiple scandals, great recessions and one great depression, five wars, and radical changes in technology. It is a tale of ambition and sacrifice, of family division and close-knit bonds of love and devotion, of industrial growth and catastrophic loss, of great joys and unbearable pain.
Why AS6500? Where did it come from? Why does it exist? Those are easy questions to answer. It came from the inspiration of angels and it exists to make your life, and your factory, more perfect. That's why, when you open the standard, you can still hear the faint echoes of the singing of angels. Actually, experts were gathered from across the country, both from the Defense Department and from industry to create the new document. They toiled away until the perfect product emerged from the fruit of their labors: Aerospace Standard AS6500, Manufacturing Management Program, published in November 2014.
How to Manage the Perfect Factory combines education and instruction with fun, laughter and motivation. The book gently pokes fun at the people and organizational barriers that the Manufacturing function must overcome to make those obstacles seem more surmountable while providing key information on implementing AS6500.
2 manuscritos completos en 1 libro
Las organizaciones se enfrentan cada vez a m s costos y una competencia cada vez mayor. Con Lean Seis Sigma puede combatir estos problemas y hacer crecer su negocio.
Lean Seis Sigma es una metodolog a fascinante que est orientada a ayudarlo a aumentar la productividad de su organizaci n y eliminar los desperdicios. La idea sintetiza dos conceptos diferentes, Lean Enterprise o Lean Manufacturing y Seis Sigma, para darle una excelente comprensi n de c mo su empresa est malgastando dinero y recursos, y qu puede hacer para evitarlo.
Este libro aborda los diferentes tipos de desperdicios y c mo Lean Seis Sigma pretende tratar cada uno de ellos, y luego le brindar todas las herramientas que necesita para comenzar a realizar un cambio efectivo en su organizaci n.
La primera parte de este libro incluye:
Al leer la segunda parte de este libro, usted:
Obtenga este libro ya para aprender m s sobre Lean Seis Sigma y Lean Analytics