Table Of ContentreCmoaminp aconmieps eotift iavlel asnizde sp raorfeit ainbl ea. Tdehsep setreaptse o ruatclien etdo IInncclluuddeess
in this book will help small organizations shorten de- CC
livery times, improve quality, and reduce costs. DD--RR
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Written with Lean implementers in mind, this text is
designed to help companies and change agents apply
the tools of Lean quickly.
Much has been written about larger companies and
lean
original equipment manufacturers (OEM) who
have implemented the Lean techniques perfected l
e
at Toyota. However, less attention has been a manufacturing
given to the special needs of smaller compa- n
nies, job shops, and “mom and pop” shops.
m
The principles of the Toyota production a
system are sound and proven. They are n
u
effective in any industry and within any
f
company. The challenge is to apply the a
c
right tool, at the right place, at the right
t
u
time, while maintaining the flexibility
r for the
and nimble nature required of smaller i
n
shops. g
While acknowledging some similarities, fo
r
about this book points out critical and distinct dif- th small shop
ferences between OEM organizations and e
s
make-to-order environments. Hybrid methods
m
the book
of implementation for the Lean techniques are
a
necessary and this book helps provide such an
l
approach. l
s
h
o
p
G A R Y C O N N E R
CONNER
Society of Society of
Manufacturing Engineers Manufacturing Engineers
www.sme.org www.sme.org
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prepages.p65 2 11/20/2000, 9:04 AM
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Society of Manufaturing Engineers
Dearborn, Michigan
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Copyright © 2001 by the Society of Manufacturing Engineers
987654321
All rights reserved, including those of translation. This book, or parts
thereof, may not be reproduced by any means, including photocopying,
recording or microfilming, or by any information storage and retrieval
system, without permission in writing of the copyright owners.
No liability is assumed by the publisher with respect to use of informa-
tion contained herein. While every precaution has been taken in the
preparation of this book, the publisher assumes no responsibility for
errors or omissions. Publication of any data in this book does not consti-
tute a recommendation or endorsement of any patent, proprietary right,
or product that may be involved.
Library of Congress Catalog Card Number: 00-134042
International Standard Book Number: 0-87263-520-1
Additional copies may be obtained by contacting:
Society of Manufacturing Engineers
Customer Service
One SME Drive, P.O. Box 930
Dearborn, Michigan 48121
1-800-733-4763
www.sme.org
SME staff who participated in producing this book:
Phillip Mitchell, Senior Editor
Rosemary Csizmadia, Production Supervisor
Frances Kania, Production Assistant
Kathye Quirk, Graphic Designer/Cover Design
Printed in the United States of America
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To my Creator, for the breath of life...
to Pamela, for taking my breath away.
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vvvvviiiii
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Acknowledgements
Robert Donnelly of Contact Lumber, Portland, Oregon. For
his unparalleled respect for learning, and for his unending dedi-
cation to the concepts and principles of continuous improvement.
I was privileged to know him for only two short years, but I will be
influenced by his energy for the rest of my life.
Tom Nielsen of Nielsen Manufacturing, Inc., Salem, Oregon.
For the opportunity to challenge my own capabilities, for showing
me the value of looking inward for opportunities and solutions.
And for the ultimate honor an employer can bestow on an employee,
enfranchisement to fully participate.
To David Dixon of Technical Change Associates, Ogden, Utah,
for affording me the chance to work with some remarkable com-
panies, and for allowing me to share the Lean Manufacturing Prin-
ciples with some unforgettable people.
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Table of Contents
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Trading Time for Dollars..................................................3
Make versus Buy .........................................................4
Evolution of a Company..................................................5
The Beginning.............................................................6
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Wheels, Spokes, and the Radar Chart ............................16
Sales, Production, and Inventory Management............19
Total Organizational Buy-in........................................20
Total Quality Management.........................................20
Lean Manufacturing Techniques .................................21
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Understanding Kaizen...................................................27
Performance Evaluation.................................................28
Value Stream MappingSM ...........................................28
Product-Quantity-Routing Analysis..............................29
Value-added versus Non-value-added Activities ..........39
Waste.......................................................................42
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Value Stream Symbols...................................................46
Four Steps to Value Stream MappingSM ...........................49
Step 1: Product Development.....................................49
Step 2: Process Design...............................................49
Step 3: Preparation ...................................................50
Step 4: Planning........................................................50
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