Brophy, A: FT Guide to Lean

review Section 2: Standard work Introduction Standard work and job classifications Improving standard work Bringing standard work to life Job breakdown sheet Standard work review Chapter 6 Lean methods and tools (part III) Section1: Idea management system Introduction Documenting ideas is crucial Idea metrics Reward and recognition Idea process flow Idea management system review Section 2: Kaizen events Introduction Kaizen stages Pre-event preparation Event workshop Confirmation phase Kaizen review Chapter 7 Lean methods and tools (part IV) Section 1: Quick changeover Introduction Why quick changeover SMED methodology Quick changeover review Section 2: Total productive maintenance Introduction Why TPM? Application of TPM TPM improvement plan TPM review Chapter 8 Lean methods and tools (part V) Section 1: Kanban Introduction Why kanban Types of kanban Kanban sizing calculation example Culture and people implications Kanban rules Supplier kanban in a hospital setting Kanban in a hospital setting Kanban review Section 2: Poke yoke Introduction Mistake proofing classifications Mistake proofing routine Poke yoke review Chapter 9 Lean methods and tools (part VI) Flow practices Introduction River and rocks analogy Batch size implications for flow A word on inventory The problem with traditional production scheduling using Materials Requirement Planning (MRP) Preconditions for flow Family identification Map the value stream Identify bottlenecks and variation Cellular flow Human implications for flow Flow practices review Part III: Leading the Lean transformation Chapter 10 Developing the Lean culture Introduction Cathedral model Model foundation Accountability process Set expectations Recognition True coaching and delegation Double diamond coaching model Constructive feedback Escalation Quantity and quality Review Acknowledgement Chapter 11 The technical side of sustaining Lean Introduction Systems thinking Hoshin Kanri strategy deployment Leadership Sustaining Lean through problem solving Lean daily management system Training within industry (TWI) Metrics Review Chapter 12 The people side of sustaining Lean Introduction Leadership Engaging people in Lean Oh, if only we had the luxury of time for improvement work! Communication Middle management A propensity for risk taking A rising tide should lift all boats Review Chapter 13 Putting it all together: The Lean Roadmap to Transformation Introduction Generic roadmap 1. Understand value through the eyes of your customers 2. Articulate the business case for transformation 3. Lean assessment 4. Value stream mapping 5. Build leadership commitment and set expectations 6. Hoshin Kanri strategy deployment 7. Management of change plan 8. Pilot Lean model area and spread plan 9. Build the Lean knowledge 10. Lean culture 11. Sustaining Lean 12. Hansei Review References and further reading Glossary Appendix Index