vii
Contents
Introduction ........................................................................................ xiii
Chapter 1 A Manufacturing Family ...................................................1
Lessons Learned ......................................................................8
Chapter 2 My First Factory ................................................................. 9
Lessons Learned ................................................................... 20
Chapter 3 Maybe Not Lean, But Lean Things ................................. 21
Do It Right the First Time ........................................................22
Product Development ...............................................................23
Problem Solving .........................................................................24
Takt Time ...................................................................................25
Standard Work ...........................................................................26
Lessons Learned ....................................................................27
Chapter 4 My First Process Improvement Project ..........................29
Leadership Nirvana ...................................................................32
Lessons Learned ....................................................................33
Chapter 5 Process Improvement Project #2 ..................................... 35
e New Owners Are at the Gate ............................................36
Lessons Learned ................................................................... 43
Chapter 6 My Lean Journey Begins ..................................................45
Water Spiders .............................................................................51
e Building Is on Fire .............................................................53
Hazardous Spill ......................................................................... 54
Lessons Learned ....................................................................55
viii  •  Contents
Chapter 7 Outboard Marine Corporation — Marine Power
Products Group ................................................................ 57
Marine Power Product Group Purchasing ............................59
Getting to Know the Gemba: e Product and the People ...62
OMC–Burnsville...................................................................62
OMC – Calhoun .................................................................. 64
Lessons Learned ................................................................... 66
Jet Skis ........................................................................................ 66
Lesson Learned .................................................................... 68
Cylinder Sleeves ........................................................................ 68
Lessons Learned ....................................................................70
More Standard Work ................................................................71
Lessons Learned ....................................................................72
Chapter 8 Japan ..................................................................................73
Mr. Yamata ............................................................................76
Are You Sure He Is Not Mad at Me? .............................79
Closing Out the Audit ......................................................... 80
Mouth Test ............................................................................. 81
Lessons Learned .................................................................... 81
Multi-Plant Inventory Reduction ............................................82
Lesson Learned .................................................................... 84
Bearing Shortage ...................................................................... 84
Lesson Learned .....................................................................85
Stickle Bricks: One-Piece Flow ................................................85
Anity Diagram ...................................................................... 86
Lesson Learned .....................................................................89
e War Room ...........................................................................89
Lesson Learned .....................................................................91
e Project Continues… ..........................................................91
Design for Manufacture and Assembly ..................................93
Proven Technology versus High-Tech ....................................94
Lesson Learned .....................................................................95
Competitive Product Comparison Project:
Boston Consulting Group ........................................................95
Lesson Learned .................................................................... 96
Contents • ix
Chapter 9 Lean Transformation # 1 .................................................97
e New Plant Manager ...........................................................98
e Incentive System ..........................................................101
Quality at the End of the Line ...............................................103
e A Cabin ...........................................................................106
Rate versus Quality .................................................................108
Lets Summarize..................................................................109
e Loop ...................................................................................110
e Transformation Begins ...................................................114
5S ................................................................................................114
Quality: Stabilizing the Processes ........................................ 120
Quarter Drills: Production Status Boards .......................... 123
Manufacturing Engineers/Process Improvement
Technicians .............................................................................. 124
Lean Training...........................................................................125
Boot Stripe Rework Reduction:
Defects, Non-Value-Added Rework ................................ 126
Lesson Learned ...................................................................127
Where to Start ..........................................................................127
Grinding and Flipping Fiberglass Decks:
Waste, Rework, Transportation, Motion............................. 134
Fiberglass Small Parts .............................................................136
Chapter 10 Components Plant .......................................................... 141
On Sabbatical ...........................................................................141
Lets Get Lean ...........................................................................146
Chapter 11 Lean Transformation #2 ................................................ 153
Process Improvement at Wellcra ........................................153
Lamination Process Improvement ...................................159
Mold Care Project ............................................................... 166
Assembly Process Improvement .......................................169
Implement 5S .................................................................. 169
Quality Process ..............................................................170
Lean Six Sigma Cost Reduction Projects .................... 173
Product Development ....................................................174
Lesson Learned ...................................................................176
x  •  Contents
Chapter 12 Improve Design Engineering Process ........................... 179
Lessons Learned ..................................................................188
Chapter 13 Improve Materials Management Process ..................... 189
Chapter 14 Lean Transformation Strategies .................................... 193
Elements of a Successful Lean Transformation ..................193
Develop a Lean Roadmap ..................................................193
Get a Lean Leader ...............................................................193
Establish a Lean Steering Committee ..............................194
Establish a Lean Resource Plan ........................................194
Establish a Lean Team in the Company ..........................195
Establish and Communicate the Lean Vision
for the Company .................................................................195
Develop the Roll-Out Plan ................................................195
Implement the Plan ............................................................196
Implement Relentless Improvement ................................196
Map and Improve Support Processes ..............................196
Move to Advanced Lean ....................................................196
Implement the Roll-Out Plan ................................................196
General Training: Lean Values, Overview ......................196
5S Implementation..............................................................196
Map and Improve Value Streams .....................................197
Implement Lean Metrics and Visual Management .......197
Total Productive Maintenance (TPM) .............................198
Align Product Development/New Product Launch
with Lean Principles ...........................................................198
Deploy and Sustain Relentless Improvement Activities ..198
Map and Improve Support Processes ..............................198
Kaizen Events ......................................................................198
Move to Advanced Lean ....................................................199
Miscellaneous Topics ............................................................. 200
Chapter 15 Various ............................................................................203
Surviving ................................................................................. 203
Organizational Politics .......................................................... 204
Leadership ............................................................................... 205
Contents • xi
How to Conduct a Process Mapping Event ........................ 206
DAY 1 .................................................................................. 207
DAY 2 .................................................................................. 207
DAY 3 .................................................................................. 207
About the Author ................................................................................ 211

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