Lean Management: Introduction and In-Depth Study of Japanese Management Philosophy

Preface
Contents
List of Abbreviations
Basics of Lean Production
	1: Introduction Lean Production
		Overview
		Right Questions
		1.1 Lean Production
		1.2 Is Lean up to Date?
		1.3 Lean at Work
		1.4 The Lean Production Roadmap
		1.5 The Expert Questions
		1.6 Introduction of Knalsch GmbH
		References
	2: Challenges
		Overview
		Knalsch GmbH: New Challenge
		2.1 Trends and Challenges
		2.2 Crisis
			Example
			Example
		2.3 Business Administration
			Example
		2.4 Customer
		2.5 Expert Questions
		2.6 Summary
			Summary on the Subject of Challenges
			Questions
		References
	3: Waste
		Overview
		Knalsch GmbH: Inefficiency
		3.1 Processes
		3.2 Value Creation
		3.3 Safety
			Example
		3.4 The Seven Types of Waste
			Example
			Example
			Example
			Example
			Example
			Example
			Example
		3.5 The Eighth Type of Waste
			Example
		3.6 Classification of Activities
			Example
		3.7 Process Analysis
		3.8 Optimization
		3.9 Expert Questions
		3.10 Summary
			Summary on the Subject of Waste
			Questions
		References
	4: Stabilization
		Overview
		Knalsch GmbH: Waiting Customers
		4.1 Loss Factors
			Example
		4.2 The 3 Mu
		4.3 Inventory
			Example
			Example
			Example
			Example
			Example
		4.4 Lead Time
			Example
			Example
			Example
			Example
			Example
			Example
			Example
		4.5 Levelling and Balancing
		4.6 Flexibility
			Example
		4.7 Expert Questions
		4.8 Summary
			Summary on the Subject of Stabilization
			Questions
		References
	5: Flow
		Overview
		Knalsch GmbH: Lack of Clarity
		5.1 Batch Size
			Example
			Example
			Example
		5.2 Layout
		5.3 Production in Flow
			Example
			Example
			Example
		5.4 Expert Questions
		5.5 Summary
			Summary on the Subject Flow
			Questions
		References
	6: Tact
		Overview
		Knalsch GmbH: Bottleneck Station
		6.1 Bottleneck
			Example
		6.2 Customer Tact Time
			Example
			Example
		6.3 Line Balancing
			Example
			Example
		6.4 Visualization of the Line
		6.5 Special Features and Cycle Time Calculations
			Example
			Example
			Example
			Example
			Example
		6.6 Dealing with Job Cuts
		6.7 Expert Questions
		6.8 Summary
			Summary on the Subject of Tact
			Questions
		References
	7: Pull
		Overview
		Knalsch GmbH: Missing Material
		7.1 Just-in-Time
		7.2 Kanban
			Example
			Example
			Example
		7.3 Kanban Environment
			Example
			Example
		7.4 One-Piece Flow in Customer Sequence
			Example
		7.5 Pacemaker
			Example
			Example
		7.6 Configurations of Flow Systems
			Example
		7.7 Expert Questions
		7.8 Summary
			Summary on the Subject Pull
			Questions
		References
	8: Value Stream
		Overview
		Knalsch GmbH: Interrelationships
		8.1 Value Stream Mapping
		8.2 Value Stream Symbols and Representation
		8.3 Value Stream Design
			Example
		8.4 Key Figures in the Value Stream
			Example
		8.5 Design Principles for the Future State Value Stream
		8.6 Expert Questions
		8.7 Summary
			Summary on the Topic of Value Stream
			Questions
		References
	9: Perfection
		Overview
		Knalsch GmbH: Quality Problems
		9.1 Understanding of Quality
		9.2 The Jidoka Principle
			Example
		9.3 Poka Yoke
			Example
			Example
		9.4 Expert Questions
		9.5 Summary
			Summary on the Subject of Perfection
			Questions
		References
	10: Standardization
		Overview
		Knalsch GmbH: What a Mess!
		10.1 Standards
			Example
		10.2 The 5S or 6S Methodology
			Example
			Example
			Example
			Example
		10.3 Visualization and Standard Description
			Example
		10.4 Examples of Standards
			Examples
			Example
			Example
			Examples
			Examples
		10.5 Role of Leadership in Standards
			Example
		10.6 Expert Questions
		10.7 Summary
			Summary on the Subject of Standardization
			Questions
		References
	11: Continuous Improvement
		Overview
		Knalsch GmbH: And Now?
		11.1 Kaizen
		11.2 Kaikaku
			Example
		11.3 PDCA Cycle
		11.4 Improvement Kata
		11.5 Sustainable Improvement
		11.6 Expert Questions
		11.7 Summary
			Summary on the Subject of Continuous Improvement
			Questions
		References
	12: Production Area Assembly
		Overview
		Knalsch GmbH: Inflexibility at the Assembly Stations
		12.1 Manual Activities
			Example
			Example
		12.2 Ergonomics
			Example
			Example
			Example
		12.3 Flexible Manpower System
		12.4 Flexible Employee Deployment
		12.5 Expert Questions
		12.6 Summary
			Summary on the Topic of Production Area Assembly
			Questions
		References
	13: Production Area Manufacturing
		Overview
		Knalsch GmbH: Machines
		13.1 Automation
			Example
			Example
		13.2 Overall Equipment Effectiveness
			Example
			Example
		13.3 Total Productive Maintenance
			Example
		13.4 Quick Changeover
			Example
			Example
			Example
		13.5 Expert Questions
		13.6 Summary
			Summary on the Topic of Production area Manufacturing
			Questions
		References
	14: Lean and Production Systems
		Overview
		Knalsch GmbH: Top Finances!
		14.1 Mass Production
		14.2 History of the Toyota Production System
		14.3 Lean and Production Systems
			Example
		14.4 Implementation
		14.5 Vision and Key Figures
		14.6 Expert Questions
		14.7 Summary
			Summary on the Topic of Lean and Production Systems
			Questions
		References
Deepening: Lean Management
	15: Introduction Lean Management
		Overview
		15.1 Lean Management
		15.2 The Lean Management Network Plan
	16: Administration
		Overview
		Knalsch GmbH: Chaos in the Administration
		16.1 Indirect Areas
		16.2 Waste in the Indirect Sector
		16.3 Methods of Analysis
		16.4 Process Visualization
		16.5 Lean in the Indirect Area
			Example
			Example
			Example
		16.6 Expert Questions
		16.7 Summary
			Summary on the Subject of Administration
			Questions
		References
	17: Product Design
		Overview
		Knalsch GmbH: New Product Design for the Knalschi 300
		17.1 Optimization of Value-Added Time
			Example
			Example
		17.2 Design for Manufacturing
			Example
		17.3 Design for X
			Example
			Example
			Examples
			Example
			Example
			Negative Example
		17.4 Measurement of Product Design
			Example
		17.5 Expert Questions
		17.6 Summary
			Summary on the Subject of Product Design
			Questions
		References
	18: Product Development Process
		Overview
		Knalsch GmbH: The Development Is at the Beginning
		18.1 Situation of Product Development
			Example
		18.2 Lean Development
		18.3 Lean Methods in Product Development
		18.4 Expert Questions
		18.5 Summary
			Summary on the Topic of the Product Development Process
			Questions
		References
	19: Production Engineering
		Overview
		Knalsch GmbH: Lean Engineering at the Swabian Lunch
		19.1 Lean Engineering
		19.2 Planning Principles
		19.3 Cardboard Engineering
		19.4 Factory Planning
		19.5 Expert Questions
		19.6 Summary
			Summary on the Topic of Production Engineering
			Questions
		References
	20: Low-Cost Automation
		Overview
		Knalsch GmbH: Expensive Robot
		20.1 Karakuri
			Example
			Example
			Example
		20.2 Low-Cost Intelligent Automation
		20.3 Implementation
			Example
		20.4 Expert Questions
		20.5 Summary
			Summary on the Subject of Low-Cost Automation
			Questions
		References
	21: Supply Chain
		Overview
		Knalsch GmbH: Assembly and Logistics: Separate or Joint?
		21.1 Line Back
		21.2 Grip-Optimized Material Placement
			Example
		21.3 Delivery
			Example
		21.4 Minomi
		21.5 Order Picking
		21.6 Supply Chain Management
			Example
			Example
		21.7 Expert Questions
		21.8 Summary
			Summary on the Supply Chain
			Questions
		References
	22: Sustainability
		Overview
		Knalsch GmbH: Hidden Costs
		22.1 Lean and Green
			Example
		22.2 Resource Efficiency
			Example
		22.3 Energy Efficiency
			Example
		22.4 Disassembly and Recycling
		22.5 Expert Questions
		22.6 Summary
			Summary on the Topic of Sustainability
			Questions
		References
	23: Key Performance Indicators
		Overview
		Knalsch GmbH: The Lion Hunt
		23.1 Key Figure Logic
			Example
			Example
		23.2 Benchmarking
		23.3 Learning to See
		23.4 Expert Questions
		23.5 Summary
			Summary on the Topic of Key Performance Indicators
			Questions
		References
	24: Policy Deployment
		Overview
		Knalsch GmbH: Everybody What he Wants
		24.1 Hoshin Kanri
		24.2 North Star and Blue Sky
		24.3 Target Break-down Process
		24.4 Expert Questions
		24.5 Summary
			Summary on the Topic of Policy Deployment
			Questions
		References
	25: Shop Floor Management
		Overview
		Knalsch GmbH: The Flop Show
		25.1 Management at the Shop Floor
		25.2 Visual Management
			Example
		25.3 Communication Structure
			Example
		25.4 Problem-solving Process
			Example
			Example
			Example
			Example
			Example
		25.5 Standard-based Process Observation
		25.6 Expert Questions
		25.7 Summary
			Summary on the Topic of Shop Floor Management
			Questions
		References
	26: Leadership and Culture
		Overview
		Knalsch GmbH: Five Times ``Who´s to Blame?´´
		26.1 Lean Leadership
		26.2 Failure Culture: Learning Culture
			Example
		26.3 Learning Organization
		26.4 Lean Transformation
			Example
		26.5 Expert Questions
		26.6 Summary
			Summary on the Topic of Leadership and Culture
			Questions
		References
	27: People
		Overview
		Knalsch GmbH: Adjusting People
		27.1 Lean and People
		27.2 People at the Centre
			Example
			Example
		27.3 Human Resources Development
			Example
			Example
		27.4 Sustainable Value Creation Through Appreciation
		27.5 Expert Questions
		27.6 Summary
			Summary on the Subject of People
			Questions
		References
	28: Digitization
		Overview
		Knalsch GmbH: Over-digitization
		28.1 Digital Processes
			Example
		28.2 Industry 4.0
		28.3 Digital Shop Floor Management
		28.4 Expert Questions
		28.5 Summary
			Summary on the Topic of Digitization
			Questions
		References
	29: Support Organization
		Overview
		Knalsch GmbH: Half Full or Half Empty?
		29.1 Lower Management Level
		29.2 Kaizen Team and Lean Experts
		29.3 Kaizen Workshop
		29.4 Lean Organization and Training Center
		29.5 Expert Questions
		29.6 Summary
			Summary on the Subject of Support Organization
			Questions
		References
	30: Consulting and Projects
		Overview
		Knalsch GmbH: How to Eat an Elephant?
		30.1 Project and Request
		30.2 Project Objective and Management
		30.3 Project Procedure
		30.4 Lean Understanding and Awareness
		30.5 Communication and Presentation
		30.6 Potentials and Economic Efficiency Calculation
			Example
		30.7 Expert Questions
		30.8 Summary
			Summary on the Subject of Consulting and Projects
			Questions
		References
	31: Change Management
		Overview
		Knalsch GmbH: A Sweaty Business
		31.1 Change
		31.2 Levels of Change
		31.3 Intrinsic Change Curve
		31.4 Resistance
		31.5 Enabling and Motivating
		31.6 Expert Questions
		31.7 Summary
			Summary on the Subject of Change Management
			Questions
		References
Annex
	32: Glossary of Japanese Lean Terms
		Overview
		References
	33: Solutions to the Exercises
		Overview
		33.1 Chapter 6: Tact
		33.2 Chapter 7: Pull
		33.3 Chapter 8: Value Stream
		33.4 Chapter 9: Perfection
		33.5 Chapter 13: Production Area Manufacturing
		33.6 Chapter 30: Consulting and Projects
Index