The Myths and Truths of Lean Transformations

Book description

This book is a crucial resource for Lean practitioners (experienced or not) who are seeking: insight on how to gain more from their Lean efforts, how to overcome resistance to change (that is, to effectively convey 'What’s in it for me?' to their business associates), and to understand how other companies have overcome the barriers to implementing Lean and incorporated it as the common-sense approach to continuous improvement.


The author shares his specific experiences with Lean transformations—some successes and some failures. His insightful perspective shows readers how the understanding of Lean progresses from theory to common sense to common practice. The Lean initiative is not merely a transformation of skills, but the development of a robust continuous-improvement culture. The book includes more than 60 case-in-point examples, across a diversified range of industries, based on the author’s hands-on experience with many multinational corporations. These case-in-point examples show transformations that have resulted in $200+ million verified annualized savings for a diversified array of industries. The author details his journey from industry Lean practitioner to a consultant in a top-tier consultancy firm to developing his own consulting practice.

Table of contents

  1. Cover
  2. Half-Title
  3. Title
  4. Copyright
  5. Contents
  6. About the Author
  7. Introduction
  8. 1 Enterprise Lean Transformation Introduction
    1. Lean Transformations: Creating & Maximizing Customer Value
    2. Change Readiness, i.e. Appetite for Change
    3. What Comprises an Enterprise Lean Transformation Model?
    4. How to Get Started with Your Enterprise Lean Transformation Initiative?
    5. Assessment Tools and Methodologies
      1. Routing By Walking Around (RBWA)
    6. Value Stream Mapping
  9. 2 Lean – The Relentless Pursuit to Eliminate Waste
    1. Muda, Muri, & Mura
    2. Value Added vs. Non-Value Added
    3. Waste – Any Amount that’s More Than the Minimum Required
    4. TIMWOOD (Figure 2.3)
      1. TIMWOOD: Transportation
      2. TIMWOOD: Inventory
      3. TIMWOOD: Motion
      4. TIMWOOD: Waiting
      5. TIMWOOD: Overproduction
      6. TIMWOOD: Over-Processing
      7. TIMWOOD: Defects
  10. 3 Lean – Lean Building Blocks – How To
    1. Flow
    2. Pull and Kanbans
    3. Leveled Production
    4. Rhythm Wheel (a.k.a. Product or Production Wheel)
    5. Cellular Manufacturing
    6. Single-Minute Exchange of Dies (SMED)
    7. Standardized Work (a.k.a. Standard Work)
      1. Routing By Walking Around (RBWA)
      2. Time Observation Sheet
      3. Standard Work Combination Sheet
      4. Process Capacity Chart
      5. Yamazumi Chart
      6. Standard Work Sheet
      7. Job Element Breakdown Sheet (JEBS
      8. Visual Aids
    8. Standard Work …
    9. Leader Standard Work
    10. Visual Management
    11. Total Productive Maintenance (TPM)
    12. Overall Equipment Effectiveness (OEE)
    13. Total Quality Management
    14. TQM’s Seven (7) Basic Quality Tools
    15. 5-Whys
    16. Failure Mode and Effect Analysis (FMEA)
    17. Workplace Organization (5S + Safety)
  11. 4 Selective Lean Transformation Case-in-Point Examples
  12. Index

Product information

  • Title: The Myths and Truths of Lean Transformations
  • Author(s): Raymond Kelly
  • Release date: September 2018
  • Publisher(s): Productivity Press
  • ISBN: 9781351584975