Table Of ContentLean Transformations
Small Medium
for and
Enterprises
Lessons Learned from Italian Businesses
Lean Transformations
Small Medium
for and
Enterprises
Lessons Learned from Italian Businesses
Arnaldo Camuffo
Boca Raton London New York
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Library of Congress Cataloging‑in‑Publication Data
Names: Camuffo, Arnaldo, author.
Title: Lean transformations for small and medium enterprises : lessons
learned from Italian businesses / Arnaldo Camuffo.
Description: Boca Raton, FL : CRC Press, 2017. | Includes bibliographical
references and index.
Identifiers: LCCN 2016024782| ISBN 9781498773638 (pbk. : alk. paper) | ISBN
9781315397825 (ebook : alk. paper)
Subjects: LCSH: Small business--Italy--Case studies. | Organizational
change--Italy--Case studies. | Reengineering (Management)--Italy--Case
studies. | Lean manufacturing--Italy--Case studies.
Classification: LCC HD2346.I8 C26 2017 | DDC 658.4/063--dc23
LC record available at https://lccn.loc.gov/2016024782
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To Elsa and Attilio, with love.
Contents
Acknowledgments .................................................................................xi
Author .................................................................................................xiii
Introduction ..........................................................................................xv
Chapter 1 Little Big Lean Champions ................................................1
1.1 Super Mario Lean: How Pietro Fiorentini
Became the Toyota of Italy ..............................................1
1.2 Ezio’s Three Donkeys: Lean Thinking
for a Better World in Frandent .......................................5
1.3 Enrico’s Lean Ovens: Unox Style and Technology .......9
1.4 The Stubborn Kata of Giorgio: Globalization,
Japanese Partnership, and Lean Thinking
at Spesso Gaskets ............................................................13
1.5 Francesco’s Cold Fusion: Making Carel Grow
with Lean Thinking ........................................................19
1.6 The Brovedani Lean System: Becoming
the Change We Want to See ..........................................26
1.7 Transforming Small and Medium Enterprises .........30
Chapter 2 Understanding the Italian Context .................................33
2.1 Sensei Luciano .................................................................33
2.2 Lean Thinking and Italy ................................................35
2.2.1 Focusing on SMEs .............................................36
2.2.2 The Wisdom of Eng. Alberto ..........................42
2.3 A Short History of the Italian Lean Movement .........43
2.3.1 From Total Quality Management to Lean
Thinking ............................................................43
2.3.2 The First Phase of Development: Quality
Circles ..................................................................45
2.3.3 The Second Phase of Development:
The Fiat Case .....................................................46
2.3.4 In the Wake of Fiat... .........................................51
2.3.5 The Third Phase of Development: Lean
Thinking Meets SMEs ......................................56
vii
viii • Contents
2.4 Giovanni’s Tires ..............................................................59
2.5 Understanding the Context of Lean
Transformations..............................................................62
Chapter 3 How to Transform SMEs .................................................67
3.1 The Lean Transformation Framework .........................67
3.2 Choosing the Strategic Problem to Be Solved.............71
3.2.1 A Matter of Strategy ..........................................71
3.2.2 A Matter of Innovation .....................................74
3.3 Improving the Work .......................................................76
3.3.1 Value Stream Mapping and Improvement .....76
3.3.2 Pursuing Just-in-Time via Flow
and Level Pull .....................................................78
3.3.2.1 Pull as a Horizontal
Coordination Principle
of Physical and Information Flows .....80
3.3.2.2 Combat Waste by Eliminating
Variability............................................82
3.4 Developing Capabilities .................................................83
3.4.1 Growing People through Problem Solving ....83
3.4.2 A3: Develop Others through Structured
Problem Solving and Management
without Authority .............................................86
3.4.2.1 A3 as a Problem-Solving Tool
and Methodology ...............................87
3.4.2.2 A3 as Management
Decision-Making Based
on Taking Responsibility ..................87
3.4.2.3 A3 as Learning Process
and People Development Tool .........88
3.4.3 Ante Litteram: TWI in Italy .............................89
3.5 Driving the Transformation: Lean Leadership
and Management System ...............................................93
3.5.1 What Does Top Management
Commitment Really Mean? .............................93
3.5.2 Building a Management System:
Management Standard Work and Gemba
Walks ...................................................................94
Contents • ix
Chapter 4 The Transformation Paths of Italian SMEs ....................99
4.1 The Italian Way to Lean Thinking ..............................99
4.2 Lean Thinking and the Specificities of Italian SMEs ...100
4.2.1 Small Size ..........................................................101
4.2.2 Agglomeration in Local Industrial Clusters ...102
4.2.3 Production Specialization in Low-Tech
Industries ..........................................................103
4.2.4 Strong Unions ..................................................104
4.2.5 Closed Governance and Family Ownership ...106
4.2.6 Production Variability and Semi-
Craftsmanship ..................................................110
4.3 Transformation Paths: Determinants
and Triggering Factors .................................................112
4.3.1 The Role of Foreign Capital ............................113
4.3.2 The Role of Industrial Customers
in International Supply Chains .....................115
4.3.3 The Role of Local Industrial Clusters ...........118
4.3.3.1 The OZ Racing Case ........................121
4.4 Lean Clubs, Communities, and Centers ..................124
4.5 Undertaking a Lean Transformation ........................126
Chapter 5 Leading Successful Lean Transformations in SMEs ....129
5.1 Acknowledging Uncertainty .......................................129
5.1.1 The Unaware .....................................................129
5.1.2 Thanks, but No Thanks ..................................132
5.1.3 “I Did It but …” ................................................133
5.1.4 The Transformers ...........................................134
5.2 De-Risking SMEs’ Lean Transformations ...............134
5.3 Will My Transformation Work? .................................137
5.3.1 Operational Performance Improvements ....138
5.3.2 Financial Performance Improvements .........140
5.4 Understanding Financial Performance
Dynamics during Transformations ...........................143
5.5 Making It Work ............................................................155
5.6 Craft Your Own Transformation Avenue .................158
Bibliography ........................................................................................161
Index ....................................................................................................171
