The Lean Book of Lean: A Concise Guide to Lean Management for Life and Business

271 Pages·2016·1.44 MB·English

by  John Earley

The Lean Book
of Lean

The Lean Book
of Lean
A Concise Guide to Lean
Management for Life
and Business
John A.A.Earley
Thiseditionfirstpublished2016
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CONTENTS
Acknowledgements xi
Preface xiii
1 IntroductiontoLean 1
ThedefinitionofLean 1
Lean–thenaturalorderofliving 3
Theshoppingtrip 3
2 TheCoreLeanPrinciples 7
Becustomerdemand-driven 8
Maximiseflow 11
Identifyandeliminatewaste 13
Declarewaronvariation 16
Organiseyourpeoplearoundoutcomesyouwant 19
Equipyourpeoplewiththerightskills 21
Clearandsimplemeasuresandcontrols 22
Definingyour“IdealState” 24
Inconclusion 25
3 MoreAboutFlow 27
Knowyourlimitations(akaconstraints) 28
Takegoodcareofyourconstraint 31
Feedmeeeeeee!!! 31
Keepinggoing 33
v
Contents
TheWhack-a-Molegameofconstraints 34
Thedishofthedayis... 35
Andourlatestofferingis... 35
Entropy 36
Continuousimprovement 36
Andthemoralofallthis... 38
Someeverydayexamplesofflow–orthelackofit! 38
Trafficlightsvs.roundabouts 39
TheDIYenthusiast 41
Theairportcheck-in 44
Inconclusion 46
4 LeanEnterprisevs.LeanManufacturing 47
Planningvs.execution 48
Prioritiesanddecisions 54
Supplierrelationships 56
Whatcanwenowprovide? 57
Gettingthebestdeal 58
Supportfunctions 59
Finance 60
Engineering 61
HR 62
Inconclusion 62
5 OrganisingforLean 65
Turningtraditionupsidedown 65
GettingaheadinaPCO 70
Thefootballteam 73
Theoryvs.reality 74
Theunfortunatebutinevitableconsequences 75
Inconclusion 76
6 MeasuringtheRightStuffandMetrics 79
What’simportant? 81
Individualperformancevs.teamoutcomes 85
vi
Contents
Thebalancedscorecard 88
Controls 89
Decisiontrees 92
Inconclusion 98
7 Leanvs.SixSigma 99
Basisforchange 100
Incrementalvs.transformational 101
Whatcomesfirst,LeanorSixSigma? 103
Inconclusion 104
8 TheLeanMindset 107
It’snotjustaboutwhatyouknow 107
Leancriticalmass 108
Leanleadership 111
Discipline 113
Leadershipvs.management 113
Knowingthedifferencebetweenaccountabilityand
responsibility 114
Consistency 114
Engagement 114
Askingtherightquestions 115
Processthinking 115
Transparencyandvisibility 116
Certification? 117
5SasafoundationforLean 119
Inconclusion 120
9 TheDreadedBusinessCase! 121
Businesscase,benefitscase,caseforaction,best
guess,what? 121
Thefinancialjustification 122
Thekickinthebackside 124
Themotivationalspeech 125
Isitworthtalkingabout? 125
Gettingmanagementboughtin 125
vii
Contents
Somebusinesscasebeartraps 126
Thedevil’sinthedetail 127
Fitforpurpose 128
Wherearethebigfishhiding? 130
Thecherrypicker 130
Inconclusion 131
10 KeystoSuccessandSustainability 133
Topreasonsforfailure 133
Howtoavoidthem 136
Buy-inatalllevels 136
Getthefundamentalsinplace 140
Workingontherightstuff 141
Lifedoesn’tstandstill 144
Inconclusion 145
11 AFewKeyTools 147
Diagnostictools 147
5Whys 148
Valuestreammapping 148
Rootcauseanalysis 154
VoiceoftheCustomer 158
Implementationtools 160
Standardisation 160
“IS–ISNOT”thinking 166
Gooddayvs.badday 168
KaizenEvents 170
Ifyoudon’thaverhythm,youcan’tdance! 175
Howitworks 176
Inconclusion 181
12 AFewWordsOnTechnology 183
What’sgood,what’snot 184
Closingthegaps 185
Inconclusion 190
viii