Table of Contents
The Lean Book of Lean
Contents
Acknowledgements
Preface
1 Introduction to Lean
The definition of Lean
Lean – the natural order of living
The shopping trip
2 The Core Lean Principles
Be customer demand-driven
Maximise flow
Identify and eliminate waste
Declare war on variation
Organise your people around outcomes you want
Equip your people with the right skills
Clear and simple measures and controls
Defining your “Ideal State”
In conclusion
3 More About Flow
Know your limitations (aka constraints)
Take good care of your constraint
Feed meeeeeee!!!
Keeping going
The Whack-a-Mole game of constraints
The dish of the day is…
And our latest offering is…
Entropy
Continuous improvement
And the moral of all this…
Some everyday examples of flow – or the lack of it!
Traffic lights vs. roundabouts
The DIY enthusiast
The airport check-in
In conclusion
4 Lean Enterprise vs. Lean Manufacturing
Planning vs. execution
Priorities and decisions
Supplier relationships
What can we now provide?
Getting the best deal
Support functions
Finance
Engineering
HR
In conclusion
5 Organising for Lean
Turning tradition upside down
Getting ahead in a PCO
The football team
Theory vs. reality
The unfortunate but inevitable consequences
In conclusion
6 Measuring the Right Stuff and Metrics
Whats important?
Individual performance vs. team outcomes
The balanced scorecard
Controls
Decision trees
In conclusion
7 Lean vs. Six Sigma
Basis for change
Incremental vs. transformational
What comes first, Lean or Six Sigma?
In conclusion
8 The Lean Mindset
Its not just about what you know
Lean critical mass
Lean leadership
Discipline
Leadership vs. management
Knowing the difference between accountability and responsibility
Consistency
Engagement
Asking the right questions
Process thinking
Transparency and visibility
Certification?
5S as a foundation for Lean
In conclusion
9 The Dreaded Business Case!
Business case, benefits case, case for action, best guess, what?
The financial justification
The kick in the backside
The motivational speech
Is it worth talking about?
Getting management bought in
Some business case bear traps
The devils in the detail
Fit for purpose
Where are the big fish hiding?
The cherry picker
In conclusion
10 Keys to Success and Sustainability
Top reasons for failure
How to avoid them
Buy-in at all levels
Get the fundamentals in place
Working on the right stuff
Life doesnt stand still
In conclusion
11 A Few Key Tools
Diagnostic tools
5 Whys
Value stream mapping
Root cause analysis
Voice of the Customer
Implementation tools
Standardisation
“IS–IS NOT” thinking
Good day vs. bad day
Kaizen Events
If you dont have rhythm, you cant dance!
How it works
In conclusion
12 A Few Words On Technology
Whats good, whats not
Closing the gaps
In conclusion
13 Getting help
We are not alone
Partnering with other companies
Best practice reference visits
Forums, blogs and social media
Institutions
Dont try this at home!
Reasons to hire and not to hire a consultant
Getting the right help
In conclusion
14 Results, What to Expect and What is Possible
Financial benefits
Revenue enhancement
Cost reduction
Cash flow
Non-financial benefits
Safety
Job satisfaction
Environment
Avoidance of…whatever
So whats in it for me?
In conclusion
15 In Conclusion
Appendix – Glossary
Afterword
Index
EULA
