Driving the Enterprise to Sustainable Excellence: A Shingo Process Overview

217 Pages·2021·26.887 MB·English

by  Gerhard Plenert

Driving the Enterprise to
Sustainable Excellence

Driving the Enterprise to
Sustainable Excellence
A Shingo Process Overview
Gerhard Plenert
A PRODUCTIVITY PRESS BOOK
First published 2021
by Routledge
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and by Routledge
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Routledge is an imprint of the Taylor & Francis Group, an informa business
© 2021 Gerhard Plenert
The right of Gerhard Plenert to be identified as author of this work has been asserted by him in accordance
with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by
any electronic, mechanical, or other means, now known or hereafter invented, including photocopying
and recording, or in any information storage or retrieval system, without permission in writing from the
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only for identification and explanation without intent to infringe.
ISBN: 9780367484019 (hbk)
ISBN: 9781003041849 (ebk)
Typeset in Minion
by Deanta Global Publishing Services, Chennai, India
Dedication
To the Love of My Life –
Renee Sangray Plenert
Who Keeps Trying to Drive Me to Excellence!!!
– Gerhard Plenert

Contents
Acknowledgments .................................................................................xi
About the Author. ...............................................................................xiii
Introduction ..........................................................................................xv
PART I The Growth of the Shingo Approach
Chapter 1 A Personal Experience .......................................................3
The Story of a Drive to Enterprise Excellence ..........................3
References (These References are utilized throughout
the book) ......................................................................................11
Chapter 2 Who Is Shigeo Shingo? ....................................................13
A Time for Reflection .................................................................13
Shigeo Shingo – a Little History ...............................................15
Shigeo Shingo – Western Influence .........................................17
References ...................................................................................20
Publications and Books by Shigeo Shingo et al. ....................20
Chapter 3 What Is the Shingo Institute and the Shingo Prize?......21
More to Reflect About ................................................................21
The Shingo Institute ...................................................................22
The Shingo Institute History .....................................................22
Driving toward Enterprise Excellence .....................................24
The Shingo Institute: Still Striving for Enterprise
Excellence ....................................................................................25
The Shingo Prize .........................................................................31
Shingo Bronze Medallion ..........................................................33
Shingo Silver Medallion .............................................................33
Shingo Prize ...............................................................................34
Publication Award ......................................................................36
vii
viii • Contents
Research Award ..........................................................................36
The Guiding Principles of the Shingo Institute and the
Shingo Model ..............................................................................37
Summary .....................................................................................39
References ...................................................................................40
PART II The Shingo Methodology
Chapter 4 Integrating the Shingo Methodology. .............................43
More to Reflect About – An Example of a Winner (In
Their Words) ...............................................................................43
REXAM – Beverage Can South America – Águas
Claras ......................................................................................43
Achievements ..............................................................................45
Lean Enterprise Achievements ...........................................45
Safety and Environmental ...................................................46
Quality ....................................................................................46
Employee Morale ..................................................................47
Delivery Performance and Cost Reductions .....................47
More about the Shingo Methodology .....................................48
Learning the Toyota Production System (TPS)
Methodology ...............................................................................49
Cultural Shift ...............................................................................51
Why Are There Three Insights and Why Are They
Important? ..................................................................................54
What Are the Characteristics of Principles and Why
Are They Important? ..................................................................55
Systems .........................................................................................57
Metrics and Results ....................................................................58
Tools .............................................................................................61
Cultural Shift ...............................................................................62
References ....................................................................................62
Chapter 5 Systems ..............................................................................65
More Reflection ...........................................................................65
Systems Transformations ..........................................................67
Contents • ix
Purpose and Systems Drive Behavior .................................67
Three Types of Systems/Systems Maps ....................................82
Definition of a Good System ....................................................90
Summary .....................................................................................91
Chapter 6 Metrics ..............................................................................95
Another Reflection .....................................................................95
The Building Blocks of Cultural Shift ......................................97
KBIs and KPIs ...........................................................................102
What Makes a Good Assessment? .........................................103
KBIs and KPIs Revisited ..........................................................104
Moving the Needle ...................................................................105
Assessing KBIs and KPIs .........................................................108
Summary ...................................................................................108
Chapter 7 Guiding Principles ..........................................................111
More Reflection .........................................................................111
The Ladder of Success ..............................................................112
Why Principles? ........................................................................112
The Shingo Model – A Review ................................................114
The Ten Principles ....................................................................116
Summary ..................................................................................120
Chapter 8 Tools ................................................................................121
More Reflection .........................................................................121
Tools ..........................................................................................122
Summary ...................................................................................132
Chapter 9 Results .............................................................................133
More to Reflect On ...................................................................133
Assessments ..............................................................................134
The Assessment Tool – An Example ......................................136
External Assessment ................................................................138
Shingo Insight ...........................................................................139
The Shingo Prize .......................................................................142