Lean transformation: cultural enablers and enterprise alignment PDF
Preview Lean transformation: cultural enablers and enterprise alignment
LEAN TRANSFORMATION Cultural Enablers and Enterprise Alignment LEAN TRANSFORMATION Cultural Enablers and Enterprise Alignment Suresh Patel CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2016 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed on acid-free paper Version Date: 20160419 International Standard Book Number-13: 978-1-49874336-5 (Hardback) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data Names: Patel, Suresh (Quality management consultant), author. Title: Lean transformation : cultural enablers and enterprise alignment / Suresh Patel. Description: 1 Edition. | Boca Raton : CRC Press, 2016. | Includes bibliographical references and index. Identifiers: LCCN 2015048105 | ISBN 9781498743365 Subjects: LCSH: Organizational effectiveness. | Product management. | Quality control. | Corporate culture. Classification: LCC HD58.9 .P3825 2016 | DDC 658.4/013--dc23 LC record available at https://lccn.loc.gov/2015048105 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com I want to dedicate this book to Mr. K. K. Nair, executive director, Ahmedabad Management Association, who encouraged me to write it after receiving excellent feedback from the delegates at the first-ever Lean Six Sigma three-day course at the AMA in June, 2011. I also dedicate this book to my dear wife, Pushpa, who had to bear many disruptions and inconveniences without my help, and without her full cooperation, this book would not have materialized. Contents Foreword by Madan Mohanka Foreword by Taiichi Ohno Acknowledgments Making It Big in Manufacturing Product and Providing Service SECTION I Lean Culture Enablers Chapter 1 Introduction History of Lean Chapter 2 Business Process Roadblocks to Lean Transformation Business Process View Managing the Purpose SIPOC Diagram Chapter 3 Embarking on the Lean Journey Shingo Process White Coat Leadership versus Improvement Leadership Nurturing the Lean Culture Respect for the Individual A Big No–No WIFM Resolution (What Is in It for Me?) Leading with Humility Chapter 4 Techniques to Change to Lean Culture Cross-Training: A Win–Win Situation Steps to Implement Cross-Training On-the-Job Training Prepare the Trainee Prepare the Training Materials and the Trainer Evaluate the Training Delivered and the Lessons Learned Coaching and Mentoring Team Management Team Dynamics Forming Storming Norming Performing Closing/Adjourning Handling Problem People Conflicts Team Decision and Consensus Building Reaching Consensus: Some Tips Suggestion Schemes The Idea Board Safe Working Environment SECTION II Principles of Continuous Improvement Process Chapter 5 Importance of Principles, Systems, and Tools in Continuous Improvement What Is a Principle? Principles Govern Consequences Chapter 6 Principles of Continuous Improvement Process Process Focus Identification and Elimination of Barriers to Flow Functional Silos Quality as a Specialized Function Cost Accounting Nine Wastes (Muda) Muri (Overburden, Stress) Mura Not Managing the Flow Matching the Rate of Production to the Level of Customer Demand Scientific Thinking Scientific Thinking Process Management by Fact Go and See Jidoka (Automation—Combination of Automation and Mistake Proofing) Integrate Improvement with Work Seek Perfection Chapter 7 Quality Is Built in the Product or Service at the Source Standard Work Successive Checks Self-Checks Visual Management Poka Yoke (Error Proofing) No Defect Passed Forward Separate Man from Machine Multiprocess Handling—Multimachine Handling Cellular (Cell) Manufacturing Stop and Fix SECTION III Continuous Improvement Process TOOIS and Practices Chapter 8 Continuous Improvement Process System Visual Workplace Transferring Vital Information into Visual Devices “The First Question Is Free” Rule of the Visual Factory 5S Standards System Complete with Implementation Guidelines 5S Activities The Benefits of 5S Are PDCA Model for 5S Implementation When to Use the Plan–Do–Check–Act Plan–Do–Check–Act Procedure 5S Audit Radar Chart Sort Key Information for Sorting
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