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The Lean Machine

Book Description

2017 Shingo Prize for Literature.

Some things never change. Harley-Davidson is still the great, iconic American motorcycle. But like many storied companies, Harley has had to evolve to stay on top, even to stay in existence. From near-extinction in the early eighties, it has risen to worldwide recognition for management excellence and innovation. The Lean Machine is an inside look at how Harley-Davidson was able to adapt in an ever-changing world and accelerate product development. Rooted in Japanese productivity improvement techniques, Knowledge-Based Product Development helped fuel Harley’s incredible period of sustained growth. Even after the company earned the PDMA Corporate Innovator Award in 2003, Dantar Oosterwal, a Harley-Davidson executive, took the improvement a quantum leap further. By implementing Lean Product Development techniques, Harley realized an unprecedented fourfold increase in throughput in half the time, powering annual growth of more than ten percent. In The Lean Machine, Oosterwal shows the day-to-day transformation at Harley and identifies universal change and improvement issues, so that companies in any industry can incorporate Knowledge-Based Innovation—with predictably excellent results.

Table of Contents

  1. Cover
  2. Half title
  3. Title
  4. Contents
  5. Acknowledgments
  6. Introduction
  7. 1 Working Hard
    1. Springtime in Paris
    2. The Concurrent Product Development Process
    3. A Reality Check
    4. Unexpected Competition
    5. Problems Late in the Development Process
  8. 2 The Harley-Davidson Environment
    1. Harley-Davidson Was Different
    2. Consensus Decision Making
    3. We Fulfill Dreams
    4. Lessons from the Dark Days
    5. The Circle Organization
    6. Consensus-Driven Organization
    7. Managing Conflict
    8. The Harley-Davidson Business Process
    9. Organizational Learning
  9. 3 Harley-Davidson’s Product Development Leadership Learning Team
    1. The PDL2T Journey
    2. Learning Organizations
  10. 4 The PDL2T
    1. Systems Thinking
    2. Learning to See the Product Development System
    3. Learningful Conversations
    4. Creating Shared Vision
  11. 5 Firefighting and the Tipping Point
    1. The MIT Connection
    2. Firefighting
    3. The Tipping Point
    4. Past the Tipping Point
    5. Lessons from Beyond the Brink
  12. 6 Cadence and Flow, Bins and Swirl
    1. The Outstanding Corporate Innovator
    2. Product Development Flow
    3. Product Development Cadence
    4. The Application of Cadence and Flow
    5. Bins
    6. Heuristic Rules of Thumb
    7. The Innovation Swirl
  13. 7 Supply and Demand
    1. The System Dynamics Model of the Motorcycle Business
    2. A Soft Landing by Reducing Shipments
    3. Generating Product Demand
    4. Developing New Products
  14. 8 A Left Turn: Implementing Lean Principles in Product Development
    1. Don’t Bring Lean Manufacturing Upstream
    2. The Roots of Knowledge-Based Product Development
    3. The Systems Approach to Flight
    4. Work Smarter, Not Harder
  15. 9 The Product Development Limit Curve
    1. Haste Makes Waste
    2. Bad Systems Beat Good People
    3. Design Rework Loops
    4. Product Development Is Predictable
  16. 10 Integration Points and False Positive Feasibility
    1. False Positive Feasibility
    2. Design Cycles and Integration Points
  17. 11 Learning Cycles
    1. The Learning Cycle
    2. Set-Based Product Development
  18. 12 Set-Based Design
    1. A New Framework for Product Development
    2. The Second Piece of the Limit Curve Puzzle
  19. 13 Leadership Learning and Pull Events
    1. The Leadership Learning Change Model
    2. Early Pull Events
    3. Creating Leverage Through Pull Events
  20. 14 Quickening Product Development
    1. Railroad Planning versus Combat Planning
    2. Establishing and Using Help Chains
    3. Using Visual Management
  21. 15 Oobeya
    1. Collaboration Using the Oobeya Process
    2. The Oobeya Process
    3. The Wall
    4. Quickening the Pace of Innovation
  22. 16 Knowledge-Based Product Development
    1. Indications of Success
    2. Creating Change
  23. Notes
  24. Index
  25. Copyright