Lean Today, Rich Tomorrow

Lean Today, Rich Tomorrow

by Joe Bichai
Released September 2014
Publisher(s): Productivity Press
ISBN: 9781482235654

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Book description

This book is about an actual Lean transformation that took place in a 100-year-old North American manufacturer's factory. Lean Today, Rich Tomorrow: Succeeding in Today's Globalization Chaos tells the story of how an obsolete factory destined for closure was transformed into the most productive North American manufacturer in its field, but this shift didn't happen without its share of obstacles.

Despite the problems the company encountered, the implementation of the Lean/TPS with JIT and Kaizen absolutely ensured its survival while many companies in the field fell under the shadow of bankruptcy. The company eliminated the bad habits associated with its antiquated push system, including piecework, batch process, and rework, and transformed its factory into a JIT/Lean philosophy-driven plant with one-piece flow, U-shaped production lines, and productivity sharing.

Telling a tale of adventure, the book guides readers through the steps taken by the company to improve processes and results over a ten-year period. This success story will give managers the tools to succeed in rallying and training a workforce to achieve Lean goals through a substantive change in culture. The book keeps the use of theory to a minimum. However, to make it useful to both students and professionals, it explains the basic concepts of the Toyota system.

Presented in a compelling story format, Lean Today, Rich Tomorrow: Succeeding in Today's Globalization Chaos is a practical work, told the way it was experienced. It avoids complex formulas, algorithms, and grand theories and instead illustrates the process used by this Canadian enterprise and its employees to achieve their successful implementation without the help of consultants.

Table of contents

  1. Front Cover (1/2)
  2. Front Cover (2/2)
  3. Contents (1/2)
  4. Contents (2/2)
  5. Preface
  6. Acknowledgments
  7. About the Author
  8. Introduction
  9. Chapter 1: Ten Years Later (1/2)
  10. Chapter 1: Ten Years Later (2/2)
  11. Chapter 2: Setting the Challenge (1/2)
  12. Chapter 2: Setting the Challenge (2/2)
  13. Chapter 3: Rethinking the Factory’s Layout and Production Philosophy (1/3)
  14. Chapter 3: Rethinking the Factory’s Layout and Production Philosophy (2/3)
  15. Chapter 3: Rethinking the Factory’s Layout and Production Philosophy (3/3)
  16. Chapter 4: Getting the Employees Involved
  17. Chapter 5: New Layout and Training (1/2)
  18. Chapter 5: New Layout and Training (2/2)
  19. Chapter 6: Reviewing the Salary, Structure, and Bonus System
  20. Chapter 7: Organizing the Work (1/3)
  21. Chapter 7: Organizing the Work (2/3)
  22. Chapter 7: Organizing the Work (3/3)
  23. Chapter 8: Overcoming the Obstacles (1/3)
  24. Chapter 8: Overcoming the Obstacles (2/3)
  25. Chapter 8: Overcoming the Obstacles (3/3)
  26. Chapter 9: Establishing a Gain-Sharing System to Stimulate Productivity (1/4)
  27. Chapter 9: Establishing a Gain-Sharing System to Stimulate Productivity (2/4)
  28. Chapter 9: Establishing a Gain-Sharing System to Stimulate Productivity (3/4)
  29. Chapter 9: Establishing a Gain-Sharing System to Stimulate Productivity (4/4)
  30. Chapter 10: Carrying Out a First Assessment and Detecting Errors along the Way (1/2)
  31. Chapter 10: Carrying Out a First Assessment and Detecting Errors along the Way (2/2)
  32. Chapter 11: Putting Kaizen into Practice in the Factory (1/3)
  33. Chapter 11: Putting Kaizen into Practice in the Factory (2/3)
  34. Chapter 11: Putting Kaizen into Practice in the Factory (3/3)
  35. Chapter 12: Tour of a Chinese Supplier: A Wake-Up Call (1/2)
  36. Chapter 12: Tour of a Chinese Supplier: A Wake-Up Call (2/2)
  37. Chapter 13: End of an Era (1/2)
  38. Chapter 13: End of an Era (2/2)
  39. Chapter 14: Winning Conditions for a Successful JIT and Kaizen Implementation Project (1/2)
  40. Chapter 14: Winning Conditions for a Successful JIT and Kaizen Implementation Project (2/2)
  41. Chapter 15: Toyota’s Lean Production System, Kaizen, and Related Concepts (1/4)
  42. Chapter 15: Toyota’s Lean Production System, Kaizen, and Related Concepts (2/4)
  43. Chapter 15: Toyota’s Lean Production System, Kaizen, and Related Concepts (3/4)
  44. Chapter 15: Toyota’s Lean Production System, Kaizen, and Related Concepts (4/4)
  45. Chapter 16: Tour of World-Class Japanese Factories (1/3)
  46. Chapter 16: Tour of World-Class Japanese Factories (2/3)
  47. Chapter 16: Tour of World-Class Japanese Factories (3/3)
  48. Chapter 17: Myths and Realities of Japanese Industry Workers (1/2)
  49. Chapter 17: Myths and Realities of Japanese Industry Workers (2/2)
  50. Chapter 18: Toyota’s Troubles (1/2)
  51. Chapter 18: Toyota’s Troubles (2/2)
  52. Chapter 19: North American Production Returns to the Fold (1/2)
  53. Chapter 19: North American Production Returns to the Fold (2/2)
  54. Appendix: Bonus Plans and Productivity Gain-Sharing Plans
  55. Glossary
  56. References
  57. Back Cover

Product information

  • Title: Lean Today, Rich Tomorrow
  • Author(s): Joe Bichai
  • Release date: September 2014
  • Publisher(s): Productivity Press
  • ISBN: 9781482235654