Download Leading the Lean Enterprise Transformation PDF

Leading the Lean Enterprise Transformation
Name: Leading the Lean Enterprise Transformation
Author: george koenigsaecker
Pages: 164
Year: 2009
Language: English
File Size: 5.37 MB
Downloads: 1
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Contents Acknowledgments ........................................................................ .........ix Introduction ........................................................................ ...................xi My Journey of Lean Learning: Eleven Corporate Transformations .................................................................1 Deere & Company .......................................................................1 Rockwell International ...............................................................3 Jake Brake (Danaher) ..................................................................4 HON Company ........................................................................ ....7 Summary ........................................................................ ..............8 What Is Lean? .....................................................................9 What Toyota Does .......................................................................9 Two Pillars ........................................................................ ..........10 Identifying and Removing Waste ...........................................10 A Problem Identifying and Problem Solving System ..........13 Summary ........................................................................ ............15 Notes ........................................................................ ....................15 Measurement Can Be Easy ..............................................17 Understanding Financial Measures: Personal Examples ........................................................................ ...........17 Toyota's True North Metrics ....................................................18 How High Is High? ................................................................... 20 ?e Four True North Metrics in Detail..................................26 Quality Improvement .....................................................26 Delivery/Lead Time/Flow Improvement .................... 28 Cost/Productivity Improvement ..................................31 Outside Purchases .............................................31 People ..................................................................31 Human Development .....................................................33 Linking the True North Metrics with Financial Measures ..................................................................35 PP7382.indb 54/24/09 7:31:48 PM


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Summary ........................................................................ ............37 Notes ........................................................................ ....................38 Value Stream Analysis Provides the Improvement Plan And Kaizen Events Make It Happen....................39 Taking a Walk to Create an Initial State VSA ...................... 40 Initial State VSA and the True North Metrics ...........41 Helping You See the Waste ............................................41 Brainstorming to Create an Ideal State Value Stream ........ 43 Creating a Future State Value Stream ................................... 43 Improvement Goals .......................................................44 Work Plan and Responsibilities ................................... 48 e Rule of 5X ........................................................................ ... 48 A Model Value Stream ............................................................. 54 e Power of Weeklong Kaizen Events ................................. 56 Summary ........................................................................ ............61 Notes ........................................................................ ....................61 Tactical Organizational Practices ...................................63 e /10 Rule ........................................................................ ......63 Designing Improvement Teams ............................................. 66 Key Event Failure Mode .......................................................... 68 e 3 Percent Guideline ............................................................69 Administrative Teams ..............................................................73 Redeployment ........................................................................ ....75 Other Lean Training .................................................................76 Summary ........................................................................ ............77 Strategic Organizational Practices ..................................79 Understanding Governance .....................................................79 Immersion ........................................................................ .........80 Guiding Coalition .....................................................................81 Communication ........................................................................ 84 Lean Simulation ..............................................................85 Strategy Deployment ......................................................85 PP7382.indb 64/24/09 7:31:48 PM


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Antibodies ........................................................................ ..........87 Lean Year by Year .....................................................................90 Year One ........................................................................ ..90 Year Two ........................................................................ ...91 Year ree ........................................................................ 91 Year Four ........................................................................ ..91 Summary ........................................................................ ............92 Building a Lean Culture ..................................................93 De ning Culture .......................................................................94 e Building Blocks of Lean/Toyota Culture ....................... 96 Serve the Customer ........................................................97 Seek What's Right, Regardless ......................................97 Decide Carefully, Implement Quickly .........................97 Candidly Admit Imperfections ....................................98 Speak Honestly and with Deep Respect ..................... 99 Go See and Listen to Learn () ........ 99 Deliver on Meaningful Challenges ...........................100 Be a Mentor and a Role Model ....................................101 e Action Plan .......................................................................102 Giving Your Leadership Team Personal Experience ....................................................................102 Daily Improvement ......................................................104 Challenging Your Team to Build Knowledge ...........105 Summary ........................................................................ ..........106 Author's Note ........................................................................ ...107 Notes ........................................................................ ..................108 Index ........................................................................ ............................109 The Author ........................................................................ ..................121 PP7382.indb 74/24/09 7:31:48 PM


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Acknowledgments My journey of lean learning continues, but it has been built on the work of many others. Starting near the beginning, it is appropriate to recog nize the people of Toyota, who have carefully distilled best practices from around the world, added unique insights of their own, and built a disci plined business system that is the benchmark for how to run an enter prise. ?e folks who began the work at Toyota, especially Taiichi Ohno, who pulled much of it together, would tell you that the Toyota model is built on a foundation of the teachings of Henry Ford, W. Edwards Deming, those who developed our WWII training methods, and others. And although this is true, the unique insights of Toyota and the compa ny's ability to create a culture that sustains this corporate learning system are truly amazing. I owe thanks to folks like Frank Petroshus of Rockwell Automotive, who supported the global learning e?ort that got me started on this path. Also, folks like Steve and Mitch Rales, who bought a company, and then let me experiment with it. And then, my principal , three members of Ohno's Autonomous Study Group, who taught me the basics of the tools and principles of Toyota Business System (TBS): Yoshiki Iwata, Chihiro Nakao, and Akira Takenaka. Perhaps most important are all the associates at Danaher and HNI/HON, who struggled with my e?orts to understand and lead in this new, lean world. I also want to thank Simpler Consulting LP for providing me with a mechanism for demonstrating that, with a solid foundation in lean prin ciples, a lean business system can be applied successfully in any work envi ronment from health care and other service industries to the military. I would also like to thank three key editors who worked with me on this manuscript: Terry Rousch (Simpler Consulting); Michael Sinocchi (senior acquisitions editor with Taylor & Francis/Productivity Press); and Tere Stou?er (freelance development editor). Of course, thanks to my wife, Charlotte, and our children, Danaka, Brooke, and Derek, who su?ered through long absences while I was on my journey of learning. None of this would be possible without them. PP7382.indb 94/24/09 7:31:48 PM


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