Implementing a Lean Management System

by Jackson, Thomas Lindsay; Jones, Karen R.

• ISBN13: 9781563270857
• ISBN10: 1563270854
• Format: Paperback
• Copyright: 1995-12-01
• Publisher: Productivity Pr

Summary

Does your company think and act ahead of technological change, ahead of the customer, and ahead of the competition? Thinking strategically requires a company to face these questions with a clear future image of itself. Implementing a Lean Management Systemlays out a comprehensive management system for aligning the firm's vision of the future with market realities. Based on hoshin management, the Japanese strategic planning method used by top managers for driving TQM throughout an organization, Lean Management is about deploying vision, strategy, and policy at all levels of daily activity. It is an eminently practical methodology emerging out of the implementation of continuous improvement methods and employee involvement. The key tools in the text build on the knowledge of the worker, multi-tasking, and an understanding of the role and responsibilities of the new lean manufacturer.

Table of Contents

Publisher's Message	p. xi
Acknowledgments	p. xvii
An Introduction To The Lean Management System
What is Lean Management?	p. 3
The Power of Lean Production	p. 4
Lean Production Requires Lean Management	p. 5
The Lean Management System	p. 7
How Lean Management Improves Strategic Planning	p. 8
A "Policy Bridge" to Implementation	p. 9
Organizational Learning	p. 9
Employee Involvement	p. 10
Cross-Functional Management	p. 10
Becoming a Zero-Waste Company	p. 12
The First Step: Recognizing Waste	p. 13
The Zero-Waste Goals	p. 14
Conclusion	p. 15
A Lean Management System Overview	p. 17
The Development Framework	p. 18
Three Cornerstones of Growth	p. 18
Nine Keys to Development	p. 19
Five Levels of Organizational Learning	p. 23
The Business Renewal Process	p. 25
The Strategic Improvement Cycle	p. 27
Delta Zero	p. 29
The Lean Management Tools	p. 32
Corporate Diagnosis: Meeting Global Standards for Excellence	p. 32
Lean Management Forms	p. 33
Lean Management Wall Charts	p. 33
The Business Renewal Process
Introducing the Nonesuch Casting Company Case	p. 40
Establishing A Vision	p. 43
Envision the Future	p. 44
Analyze Core Capabilities	p. 45
Revise the Vision	p. 46
Deploy the Vision	p. 48
Building a Development Strategy	p. 49
Conducting a Corporate Strategy	p. 50
Review Strategic Information	p. 52
Market Position	p. 52
Competitor Analysis	p. 53
Define Strategic Keys	p. 55
Produce a Development Plan	p. 57
The Strategic Improvement Cycle
Phase I: Focus	p. 65
Select an Improvement Theme and Set an Overall Target	p. 69
Selecting the Theme	p. 69
Defining a Target	p. 72
Define Critical Keys and Targets for Each	p. 74
Determine Critical Control Points	p. 78
Write Proposed Deployment Plans	p. 82
Estimate Financial Impacts	p. 85
Summarize	p. 88
Phase II: Standardization	p. 91
The Process of Standardization	p. 92
Focus Team Activities	p. 94
Organize Deployment Teams	p. 94
Announce Annual Policy and Transmit Deployment Plans	p. 95
Play Catchball with Deployment Teams	p. 96
Finalize Budgets	p. 96
Summarize	p. 97
Deployment Team Activities	p. 97
Collect, Analyze, and Evaluate Data	p. 97
Determine Critical Checkpoints	p. 99
Play Catchball	p. 101
Write and Transmit Action Plans	p. 104
Implementation Activities by Action Teams	p. 107
Draw up Workcenter Plans	p. 108
Assign Targets and Tasks for Worketams	p. 109
Set Personal Targets and Tasks	p. 113
Apply Reliable Methods and Improve Current Standards	p. 117
Phase III: Adherence	p. 119
Action Team Adherence Activities	p. 119
Create a Visual Information System	p. 120
Maintain a Reporting System	p. 121
Support Continuous Learning in the Workplace	p. 129
Deployment Team Adherence Activities	p. 129
Focus Team Adherence Activities	p. 132
Complete the Plan Summary	p. 132
Conduct a Corporate Diagnosis	p. 135
Phase IV: Reflection	p. 139
Collect Information	p. 140
Identify Critical Performance Gaps	p. 140
Identify Emergent Gaps and Barriers	p. 141
Analyze Gaps and Barriers	p. 142
Summarize	p. 143
Postscript: Continuing the Cycle of Organizational Learning	p. 147
For Further Reading	p. 151
About the Authors	p. 157
Index	p. 159
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