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Contents Fundamentals ........................................3 Basics ..................................................3 Classics ................................................6 Shopfloor Series ..................................8 Culture ................................................10 Strategy ..............................................14 Metrics ................................................20 Industries/Functions ............................22 Healthcare ........................................22 Office ................................................33 IT ......................................................38
Making a few quality improvements of our own, we’ve upgraded our website to make it even easier to find the information and resources that you need.
Accounting/Finance ..........................41 Product Development ........................42
Also check out these new features:
Job Shop and Process Management ..43
• Featured Lean Books includes the newest publications and essential classics, as well as a selection of books that will start you on your Lean journey
Supply Chain Management ..............44 Methods & Tools ................................48 Value Stream Management ................48 Problem Solving ................................49 5S ......................................................50 Mistake-Proofing ................................52 Quick Changeover ............................54
• Lean Insider Blog provides discussion on news, research and trends on all things Lean • Productivity Press in the News collects the latest reviews and articles about our books and authors
Cellular Manufacturing ......................56 Kanban ..............................................57 Six Sigma/Statistics ............................58
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Total Productive Maintenance ............60
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FUNDAMENTALS-BASICS Creating a Lean Culture Tools to Sustain Lean Conversions, Second Edition David Mann “The new insights included in this second edition of Creating a Lean Culture affirm our examiners recommendations in 2006 to recognize this original work with the Research and Professional Publication Award." — Robert D. Miller, Executive Director, The Shingo Prize for Operational Excellence
Now updated to include non-factory environments, the new edition of David Mann’s International Bestseller: • Shows how to implement Lean management in discrete manufacturing, office, healthcare, and process manufacturing environments • Shows the difference between measuring improvement through results and through processes • Includes two versions of the Lean management assessment (available online) one for manufacturing and one for administrative, technical, and professional settings This crucial work has been translated into Portuguese, Russian, Thai, and Chinese. Catalog no. K10570, March 2010, 316 pp., Soft Cover, ISBN: 978-1-4398-1141-2, $39.95 / £25.99
Andy & Me Crisis and Transformation on the Lean Journey, Second Edition Pascal Dennis Praise for the first edition "… one of the best books I’ve read in a long time on the subject of Lean and the Toyota Production System. Don’t be fooled by how simplistic some of the author’s solutions appear. If properly taught, and then religiously utilized, they will significantly improve your organization. Pascal Dennis is not only a seasoned ‘Sensei’ but a good storyteller as well." — Steve Pontbriand, Senior Vice President, Systems Control
In an era when auto companies are being propped up instead of profiting, many firms are revisiting this award-winning fictionalized account and the very real lessons it teaches. The second edition of this entertaining parable emphasizes practicality and a can do attitude in the face of all challenges, big and small. This edition adds study questions that highlight critical leadership lessons and includes corresponding notes that provide up-front guidance. The author is a Toyota veteran with two decades of experience as a consultant in Lean management and manufacturing. Catalog no. K11209, November 2010, c. 216 pp., Soft Cover, ISBN: 978-1-4398-2538-9, $29.95 / £18.99
Lean Production for Competitive Advantage A Comprehensive Guide to Lean Methodologies and Management Practices John Nicholas Loyola University Department of Operations, Chicago, Illinois, USA
Based on the author’s three decades of teaching experience, this text introduces the Lean philosophy and illustrates the effective application of Lean tools with case studies from a range of industries. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, preventive maintenance, standard operations, as well as synchronizing and scheduling Lean operations. Designed for those with a basic foundation in production and operations management, the text provides a complete understanding of fundamental Lean principles. Catalog no. K11112, July 2010, 527 pp., ISBN: 978-1-4398-2096-4, $79.95 / £48.99
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FUNDAMENTALS-BASICS Mr. Lean Buys and Transforms a Manufacturing Company The True Story of Profitably Growing an Organization with Lean Principles Greg Lane "…. Assuming you subscribe to management being synonymous with improvement, you are sure to come away from this book with a clear plan for a few new improvements." — Xavier Pujol, Plant and Site Manager, Continental Corporation
This is the true story of how, armed with only Lean improvement methodologies, a specially trained Toyota Lean expert purchased a business he knew nothing about, applied Lean techniques, and succeeded in doubling sales and increasing profitability. With humility and humor, the author recounts his successes and failures, introduces his key employees and their struggles with change, and provides motivation and simple ideas for all readers looking to improve their businesses. Catalog no. K10777, January 2010, 296 pp., ISBN: 978-1-4398-1516-8, $39.95 / £25.99
Toyota Kaizen Methods Six Steps to Improvement Isao Kato and Art Smalley This workbook is the first of its kind to document and outline the actual kaizen practices taught within the Toyota Motor Corporation to develop leadership skills and personal responsibility close to the manufacturing floor. By explaining in full context the six basic kaizen principles that govern Toyota, the authors enable readers to improve their own skills and those of their employees making full use of the kaizen approach. The text examines simple analytic methods for work elements, time, motion, production lead-time, machine losses, and standardized work. Catalog no. K11748, October 2010, c. 151 pp., Soft Cover, ISBN: 978-1-4398-3853-2, $49.95 / £31.99
Working with Machines The Nuts and Bolts of Lean Operations with Jidoka Michel Baudin "… very informative … easy to read … it will help many readers understand how to incorporate the roles of machines into modern-day management." — Imai Masakki, Founder, Kaizen Institute
Exploring the modern role of machines, this book explains how performance differences factory to factory can be directly linked to how people use machines. It covers human interfaces for individual machines, management of monuments and common services, automation, maintenance, and production control. It provides strategies and tools for making technical and managerial decisions about machines that will improve efficiency and profitability. The author emphasizes the importance of the jidoka pillar of the Toyota Production System and discusses ways to group machines together into cells. Catalog no. PP7329, 2007, 368 pp., ISBN: 978-1-56327-329-2, $59.95 / £38.99
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FUNDAMENTALS-BASICS Lean Production Simplified Second Edition A Plain-Language Guide to the World's Most Powerful Production System Pascal Dennis "Lean Production Simplified is both enlightening and informative for all levels of Lean learners. It is written from a very human perspective. — Anne Stevens, VP, North America Vehicle Operations, Ford Motor Company
A Shingo Prize Winner for Excellence in Manufacturing Research, this book delivers an inside practitioner’s view of Lean manufacturing. It looks at the origins and underlying principles of Lean, discusses practical problem solving for Lean production, and details activities that support involvement, including kaizen circles and suggestion systems. It covers the Lean Improvement Process; Production Physics and Little's Law; Value Stream Thinking; the Hoshin Planning and Execution Tree diagram, and Problem Solving by way of the Five Why method. Catalog no. PP7356, 2007, 192 pp., Soft Cover, ISBN: 978-1-56327-356-8, $39.95 / £24.99
Insights on Implementation A series of books as inspirational as they are informative Insights on Implementation, a book series from Productivity Press, brings together a variety of case studies around specific topics important to those organizations thinking about or in the process of implementing lean improvements or those thinking about taking their lean improvements to the next level. It gives hands-on executives and managers the opportunity to learn from the direct experiences of others in the same position. While each book provides a number of inspiring examples, the collections also include attempts that came up short of the mark, as it is better to learn from others’ missteps rather than from your own. • Written in a conversational, easy-to-read style • Provides practical, in-depth descriptions of typical lean concerns • Shows you methods used to engage all the stakeholders in an organization • Affordably priced to share with all key personnel in your organizations
Lean Supply Chain: Collected Practices and Cases Catalog no. PP7330, 2006, 144 pp., ISBN: 978-1-56327-330-8, $16.95 / £10.99
The Lean Office: Collected Practices and Cases Catalog no. PP7316, 2005, 128 pp., ISBN: 978-1-56327-316-2, $16.95 / £10.99
Lean Culture: Collected Practices and Cases Catalog no. PP7326, 2005, 160 pp., ISBN: 978-1-56327-326-8, $16.95 / £10.99
Visual Tools: Collected Practices and Cases Catalog no. PP7331, 2006, 144 pp., ISBN: 978-1-56327-331-4, $16.95 / £10.99
TPM: Collected Practices and Cases Catalog no. PP7328, 2006, 144 pp., ISBN: 978-1-56327-328-5, $16.95 / £10.99
Improving Flow: Collected Practices and Cases Catalog no. PP7332, 2006, 160 pp., ISBN: 978-1-56327-332-2, $16.95 / £10.99
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FUNDAMENTALS – CLASSICS JIT Implementation Manual The Complete Guide to Just-in-Time Manufacturing, Second Edition (6-Volume Set) Hiroyuki Hirano Known as the JIT Bible in Japan, this six-volume set presents the genius of Hiroyuki Hirano who leaves no detail to chance in explaining how to implement and maintain a Just-in-Time manufacturing program. Encyclopedic in scope, this new re— released edition provides information on every aspect of JIT, from its philosophical underpinnings to the myriad systems, techniques, and tools for every factory setting. While each volume is available individually, we have affordably priced the set to honor Hirano’s recommendation that readers "avoid taking a piecemeal approach… The overall flow is the most important aspect of production, and the key ingredient for creating a good overall flow is comprehensive improvement… ." Volume 1 — The Just-In-Time Production System Volume 2 — Waste and the 5S’s Volume 3 — Flow Manufacturing – Multi-Process Operations and Kanban Volume 4 — Leveling – Changeover and Quality Assurance Volume 5 — Standardized Operations – Jidoka and Maintenance/Safety Volume 6 — JIT Implementation Forms and Charts Catalog no. PP9013, 2009, 999 pp., Soft Cover, ISBN: 978-1-4200-9013-0, $199.95 / £121.00
Inside the Mind of Toyota Management Principles for Enduring Growth Satoshi Hino “For anyone interested in understanding Toyota's functions and capabilities as a total system, this book is a must read." — Professor Fujimoto Takahiro, University of Tokyo
"The most thorough explanation of the unique learning culture that Toyota has built, which is the real key to their phenomenal business success" — George Koenigsaecker, Simpler Consulting Inc.
Winner of a Shingo Prize for Excellence in Manufacturing Research, this book presents a fresh and detailed analysis of Toyota’s essential management system, where the goal is not simply to mimic Toyota’s formula, but to learn from it and, in doing so, surpass it. Catalog no. PP7300, 2006, 352 pp., ISBN: 978-1-56327-300-1, $55.95 / £35.99
A Study of the Toyota Production System From an Industrial Engineering Viewpoint Shigeo Shingo and Andrew P. Dillon The green book that started it all, this is first book on JIT in English written from the engineer's viewpoint. When Omark Industries bought 500 copies and studied it company-wide, Omark became the US pioneer in JIT. It provides Dr. Shingo's classic industrial engineering rationale for implementing process-based rather than operational improvements in manufacturing. He explains the basic mechanisms of the Toyota Production System, examines production as a functional network of processes and operations, and then discusses the organization-wide mechanism necessary to make JIT possible in any manufacturing plant. He demonstrates new ways to think about profit, inventory, waste, and productivity. Catalog no. PP9917, 1990, 304 pp., ISBN: 978-0-915299-17-1, $59.95 / £38.99
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FUNDAMENTALS – CLASSICS Non-Stock Production The Shingo System of Continuous Improvement Shigeo Shingo Shingo, whose work at Toyota led to Just in Time Manufacturing, teaches how to implement non-stock production in JIT operations. The culmination of his extensive writings on production and improvement, this book provides a companion to his other landmark books on key elements of JIT, including SMED and poka-yoke. He covers basic concepts for improving production, and in examining various production systems, exposes fundamental flaws in European and American production philosophies. He also delves into the scientific thinking mechanism -- a new approach to improvement, and discusses production functions in both authorized stock and non-stock production environments. Catalog no. PP7347, 2006, 479 pp., Soft Cover, ISBN: 978-1-56327-347-6, $55.95 / £35.99
Toyota Production System Beyond Large-Scale Production Taiichi Ohno In this classic text, Taiichi Ohno -- inventor of the Toyota Production System and Lean manufacturing -- shares the genius that sets him apart as one of the most disciplined and creative thinkers of our time. Combining his candid insights with a rigorous analysis of Toyota's attempts at Lean production, Ohno explains how Lean principles can improve any production-oriented endeavor. A historical and philosophical description of just-in-time and Lean manufacturing, this work is a must read for all students of human progress. On a more practical level, it continues to provide inspiration and instruction for those seeking to improve efficiency through the relentless elimination of waste. Catalog no. PP9914, 1988, 176 pp., ISBN: 978-0-915299-14-0, $49.95 / £31.99
Today and Tomorrow Commemorative Edition of Ford's 1926 Classic Henry Ford "Today and Tomorrow is timeless. Within its pages, we find Henry Ford's philosophy of Lean manufacturing -- the roots of today's Ford Production System." —James J. Padilla, Group Vice President, Ford North America
Henry Ford is the man who doubled wages, cut the price of a car in half, and produced over 2 million units a year. Time has not diminished the progressiveness of his business philosophy, or his profound influence on worldwide industry. The modern printing of Today and Tomorrow features an introduction by James J. Padilla, Group Vice President, Ford North America. It also includes an enhanced selection of photos illustrating the processes and facilities Ford covers in the text. Taiichi Ohno acknowledged that a key stimulus to JIT was his close reading of this book. Today, these same ideas are re-emerging to revitalize American industry in new ways. Catalog no. PP9936, 2003, 288 pp., ISBN: 978-0-915299-36-2, $39.95 / £24.99
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FUNDAMENTALS – SHOPFLOOR SERIES
Train Your Workforce with Our Shopfloor Series
Autonomous Maintenance for Operators
Pull Production for the Shopfloor
Introduces operators to equipment maintenance and motivates them to take ownership of their equipment.
Gain knowledge that can be used to understand, plan, and implement pull production.
ISBN: 978-1-56327-082-6 $28.95 US £17.99 UK
ISBN: 978-1-56327-274-5 $28.95 US £17.99 UK
Cellular Manufacturing Introduces production teams to cellular manufacturing concepts and prepares them to help in the design of new cells. ISBN: 978-1-56327-213-4 $28.95 US £17.99 UK
Standard Work for the Shopfloor Establishes the best activities and sequence steps to maximize performance and minimize waste. ISBN: 978-1-56327-273-8 $28.95 US £17.99 UK
Just-in-Time for Operators
Kaizen for the Shopfloor
Shares lean manufacturing principles of waste reduction, inventory control, cell layout, & support techniques.
Takes you through the steps in conducting an effective kaizen event.
ISBN: 978-1-56327-133-5 $28.95 US £17.99 UK
TPM Team Guide Emphasizes integration of TPM with production management. Perfect for supervisors, operators, facilitators, and trainers. ISBN: 978-1-56327-079-6 $28.95 US £17.99 UK
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ISBN: 978-1-56327-272-1 $28.95 US £17.99 UK
Identifying Waste on the Shopfloor An excellent guide to understand, identify, and eliminate waste on the Shopfloor. ISBN: 978-1-56327-287-5 $28.95 US £17.99 UK
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FUNDAMENTALS – SHOPFLOOR SERIES
The Productivity Press Development Team: Recipients of the Shingo Prize!
Kanban for the Shopfloor
TPM for Every Operator
Provides the information needed to understand, plan, and implement kanban.
Focuses on basic TPM principles, autonomous maintenance, and safety.
ISBN: 978-1-56327-269-1 $28.95 US £17.99 UK
ISBN: 978-1-56327-080-2 $28.95 US £17.99 UK
Quick Changeover for Operators
OEE For Operators
Features Shingo’s SMED approach for shortening setups and boosting manufacturing flexibility.
Makes overall equipment effectiveness accessible to workers who have the most to gain from improving equipment.
ISBN: 978-1-56327-125-0 $28.95 US £17.99 UK
ISBN: 978-1-56327-221-9 $28.95 US £17.99 UK
Mistake-Proofing for Operators
Focused Equipment Improvement
Introduces poka-yoke methods for preventing defects by monitoring process conditions at the source.
Gives your TPM teams a powerful framework for further improving equipment performance. ISBN: 978-1-56327-081-9 $28.95 US £17.99 UK
ISBN: 978-1-56327-127-4 $28.95 US £17.99 UK
5S for Operators TPM for Supervisors Gives supervisors a practical and to-the -point understanding of the benefits of TPM and their role in making it successful. ISBN: 978-1-56327-161-8 $28.95 US £17.99 UK
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This book will teach your workers the basics of: Sort, Set in Order, Shine, Standardize, and Sustain. Filled with illustrations, page headers, chapter summaries, and application questions, it proves that learning can be fun. ISBN: 978-1-56327-123-6 $28.95 US £17.99 UK
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CULTURE Staying Lean Thriving, Not Just Surviving Peter Hines, Pauline Found, Gary Griffiths, and Richard Harrison Originally self-published, this report was awarded a 2009 Shingo Prize. It draws on the experience of a real multi-national multi-site company that has successfully implemented Lean in its manufacturing and commercial sectors with great results. In presenting a model of sustainable change, the text addresses the elements of successful Lean management that are often difficult to emulate as well as the more visible features of process management. Stressing a rigorous approach, this case study covers a complete six-year Lean transformation involving the application of three distinct roadmaps. Catalog no. K11258, January 2011, c. 128 pp., Soft Cover, ISBN: 978-1-4398-2617-1, $39.95 / £25.99
What Works for GE May Not Work for You Using Human Systems Dynamics to Build a Culture of Process Improvement Lawrence Solow and Brenda Fake "Want to increase your success rate on process improvement? Read this book and incorporate its ideas into your approach." —Warren Wilhelm, President, Global Consulting Alliance
"This book will make your Lean Six Sigma efforts stick." —John V. Grice, Industrial Statistician, Six Sigma Master Black Belt
Focusing on Lean, Six Sigma, and Human Systems Dynamics, this guide provides new tools for managing and sustaining process improvement in today’s complex non-linear environments. With more than 50 combined years of change management and process improvement consulting experience, the authors offer valuable practical insights for creating dynamic organizational change. Catalog no. K11248, May 2010, 206 pp., ISBN: 978-1-4398-2599-0, $39.95 / £25.99
A Culture of Rapid Improvement Creating and Sustaining an Engaged Workforce Raymond C. Floyd “Ray Floyd describes what a high contribution, autonomous action organization is and why you want and need one.” — David Roberts, Director Product Development (retired), The Proctor & Gamble Company
Filled with lessons garnered from practical experience, this text is based on Ray Floyd's 40 years of industrial management, including his more than 20 years at Exxon Mobil. He is a Shingo Prize winner and also holds the unique distinction of having led businesses from two different industries that were both recognized by IndustryWeek as being among the Best Plants in America. The work identifies and demonstrates the application of the management tasks required to inspire and develop a culture of improvement that actively involves all stakeholders. If you approach the task of improvement with full participation, improvement is not just possible, but inevitable. Catalog no. PP7378, 2008, 328 pp., ISBN: 978-1-56327-378-0, $41.95 / £26.99
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CULTURE Implementing TWI Creating and Managing a Skills-Based Culture Patrick Graupp and Robert J. Wrona Featuring modernized implementation strategies employed in Lean initiatives today, this volume describes the experiences of a variety of companies using TWI, more than 60 years after Training within Industry turned the U.S. into the industrial giant that won World War II. Based on their experience implementing TWI in companies across the world, Graupp and Wrona, highlight critical elements and point out key stumbling blocks to a successful TWI implementation. Designed as a hands-on manual, the book includes case studies as well as a variety of updated tools and templates. Catalog no. K11246, November 2010, c. 498 pp., ISBN: 978-1-4398-2596-9, $49.95 / £31.99
The TWI Workbook Essential Skills for Supervisors Patrick Graupp and Robert J. Wrona Winner of a Shingo Prize for Excellence in Manufacturing Research, this critically acclaimed text continues to reintroduce the U.S. to TWI. It demonstrates efficient ways to instruct employees on how to perform jobs safely and conscientiously; looks at ways to produce more quality products in less time through the handling of workforce, machines, and materials; and shows how to improve performance with employee relations that preemptively prevent problems. The authors include exercises that can be applied to readers’ own worksites. A companion CD provides forms needed to complete the exercises and implementation case studies. Catalog no. PP7315, 2006, 224 pp., Soft Cover, ISBN: 978-1-56327-315-5, $49.95 / £31.99
Training Within Industry The Foundation of Lean Donald Dinero "This excellent historical overview … will educate decision makers on what the Job Instruction, Job Methods and Job Relations programs are, how each is delivered, and the significant impact each TWI program can have on their organization." — Robert J. Wrona
Winner of a Shingo Prize for Excellence in Manufacturing Research, this book elucidates the history and application of the four modules that comprise TWI. The author explores a crucial piece of a Lean initiative that is often overlooked. He demonstrates how to train employees to perform tasks quickly with minimal waste, improve processes using existing resources, solve personnel problems in an analytical manner that allows employees to stay focused, and develop robust training plans to meet the particular needs of a specific plant. Includes a generic TWI organizational chart, and a CD with early TWI training materials. Catalog no. PP7307, 2005, 352 pp., ISBN: 978-1-56327-307-0, $49.95 / £31.99
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CULTURE Lean Safety Transforming your Safety Culture with Lean Management Robert Hafey "If the strength of your company is dependent on developing an exceptional workforce, then start where it matters most – providing the tools for a safe, efficient and involved employee group. This book can be the roadmap to get you there." — Jerry Paulson, former President and CEO, Flexco
Written by a leader in Lean implementation with more than 30 years of experience, this book provides the knowledge necessary to both assess and improve safety programs through use of Lean tools and techniques. The text focuses on cultural change, leadership, improvement methodologies, investigations designed to get at root causes, and the metrics required to track and maintain a fluid approach to safety. The author takes lessons learned from Lean and applies them to the building of a world-class safety-first organization. Catalog no. K10844, January 2010, 186 pp., Soft Cover, ISBN: 978-1-4398-1642-4, $39.95 / £25.99
Developing a Lean Workforce A Guide for Human Resources, Plant Managers, and Lean Coordinators Chris Harris and Rick Harris "… required reading for Human Resource Managers in organizations implementing Lean systems." — David Saylor, Managing Director of Manufacturing, Masco Builder Cabinet Group
With an HR perspective, veteran consultants Chris Harris and Rick Harris walk readers through a simple, step-by-step proven method for transforming a mass production workforce into a Lean thinking one that possesses the necessary skills, training, and attitude to march in a new direction. They explain the role of human resources in a Lean-oriented facility, emphasizing systematic ongoing training for all employees. They also discuss the value of promoting employees from within and the importance of flexibility. This critically acclaimed book includes sample training sessions with explanations. Catalog no. PP7348, 2007, 160 pp., Soft Cover, ISBN: 978-1-56327-348-3, $49.95 / £31.99
Learning Organizations Developing Cultures for Tomorrow's Workplace John Renesch and Sarita Chawla "In a rich dialogue of many voices, this book explores some key ideas of an emerging new management paradigm. Community, networks, feedback, self-organization, and learning are essential aspects of understanding business organizations as living systems. For managers and entrepreneurs in the twenty-first century this perspective will be vital." — Fritjof Capra, Author, The Turning Point
Bringing together 32 essays written by 39 highly respected organizational leaders and scholars, this volume provides a wide range of perspectives on how workplace cultures both cultivate and inhibit organizational learning and development. Lead authors include Harvard's Rosabeth Moss Kanter, London Business School's Charles Handy, and MlT's Fred Kofman and Peter Senge. The essays in this collection are organized in four sections: Guiding Ideas, Theories/Methods/Processes, Infrastructure, and Arenas of Practice. Catalog no. PP7340, 2006, 572 pp., Soft Cover, ISBN: 978-1-56327-340-7, $49.95 / £31.99
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CULTURE Stories from My Sensei Two Decades of Lessons Learned Implementing Toyota-Style Systems Steve Hoeft "Steve is a real sensei. His presentations captivate students. His enthusiasm is contagious. When Steve writes about the TPS house it is not just an abstraction. It is something he lives." — Jeffrey K. Liker, author of The Toyota Way
In this unique volume, the author, a Toyota-trained expert, employs memorable stories from his own learning experiences to teach Toyota Production System principles. Organized according to the Toyota House model of Lean, the stories provide a framework for understanding. Each story is complemented by questions that encourage the reader to reflect on how each principle applies in their own business, process, or life. Each chapter includes a more detailed description of the tools and principles in the respective part of the house model. Catalog no. K10850, January 2010, 180 pp., ISBN: 978-1-4398-1654-7, $29.95 / £18.99
Feedback Toolkit 16 Tools for Better Communication in the Workplace Rick Maurer "This clearly written book is like having your own personal coach assisting you with techniques that foster productive interactions. … especially useful for managers and employees in organizations that do not have internal human resources development staff." — Nedra Weinstein, Manager, Human Resource Development, PBS
Used well, feedback can motivate people to their highest level of performance. Rick Maurer's Feedback Toolkit provides managers with a very accessible and wellorganized guide for creating and maintaining open and productive communication in the workplace. Detailing a systematic approach to enhancing communication throughout an organization, it provides 16 practical and creative approaches for giving and receiving feedback. It covers how to maximize feedback from your boss, from peers, and from a coach, as well as feedback from questionnaires. A new edition of the Feedback Toolkit will be available in January 2011 – ISBN: 978-1-4398-4093-1 Catalog no. PP7056, 1995, 112 pp., Soft Cover, ISBN: 978-1-56327-056-7, $16.95 / £10.99
Sustaining Lean Case Studies in Transforming Culture Edited by
Association for Manufacturing Excellence Maybe the greatest challenge facing those implementing Lean is how to sustain momentum. While implementation tools are critical, the most essential tool that managers require is confidence. One way to gain that confidence is to hear the stories of others who have survived the same challenges. This volume, the third compilation of articles published in AME’s well-regarded Target magazine, answers that need. While a few of the articles broadly discuss transformation, the vast majority present highly illuminating and often inspirational case studies that show how wellknown companies have successfully transformed lackluster cultures into ones where prosperity thrives. Catalog no. PP3791, 2009, 144 pp., Soft Cover, ISBN: 978-1-4200-8379-8, $20.95 / £13.99
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STRATEGY Critical Success Factors Simplified Implementing the Powerful Drivers of Dramatic Business Improvement Marvin T. Howell "If you want to be a senior executive or project leader, or if you are a senior executive or project leader and want to keep your job, read this book and put its principles to work." —Joseph A. "Bud" Ahearn, Major General, US Air Force (retired), Vice Chairman, emeritus, CH2MHill, Ltd
This book simplifies the identification, measurement, and use of CSFs to successfully implement strategies, manage projects, and improve processes. It provides measurement techniques for tracking progress, highlighting problem areas, and facilitating improvements. The first part covers the background of CSFs, including Rockart's CSF Method, along with two techniques for identifying external CSFs, and a simple process to generate internal CSFs. The second part addresses specific applications of CSFs, from strategic planning to individual pursuits. Catalog no. K10558, January 2010, 156 pp., ISBN: 978-1-4398-1117-7, $39.95 / £25.99
From Belief to Knowledge Achieving and Sustaining an Adaptive Culture in Organizations Neil Douglas and Terry Wykowski “…well written, thoughtful and thought provoking … offers leaders and scholars of change a considered opportunity to explore the transitions along the continuum from belief to knowledge that can lead to sustainable change.” — Sue Dopson, Said Business School, University of Oxford
Rather than offer simple recipes, this book shows how good leaders can evolve and sustain an adaptive culture that develops knowledge through purposeful human interaction. It explores key dynamics of learning, considers the diversity of beliefs present in any group, and demonstrates ways to explore and encourage the potential of both the group and individuals within the group. It demonstrates the importance of unearthing beliefs to find the roots and persistent influences that preserve them. It gives us a much broader definition of organizational knowledge than that associated with IT and the currently popular idea of knowledge as an asset. Catalog no. K11694, August 2010, 261 pp., ISBN: 978-1-4398-3734-4, $59.95 / £38.99
Escape the Improvement Trap Five Ingredients Missing in Most Improvement Recipes Michael Bremer and Brian McKibben “We have all suffered from the difficulty of sustaining improvement, and this book lays the sustaining process in a simple common sense way that is easy to read.” — Basem Hishmeh, Chairman, Sigma-Netics, Inc.
Despite performance improvement initiatives such as Lean, Six Sigma, and SupplyChain Management, only a handful of companies actually break out of the pack to transform their enterprise. Providing helpful methods and metrics for effecting true change, this book demonstrates how to avoid common improvement traps that inhibit many organizations from rising above the rest. Catalog no. K10932, September 2010, 319 pp., Soft Cover, ISBN: 978-1-4398-1796-4, $49.95 / £31.99
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STRATEGY Leading the Lean Enterprise Transformation George Koenigsaecker "Any senior executive serious about leading a Lean transformation should start here.” — Larry Culp, president and CEO, Danaher Corporation
"This truly worked for us, and continues to make our Air Force better. The message comes with great stories and legendary examples to make Leading the Lean Enterprise Transformation readable for all." — Michael W. Wynne, 21st Secretary, United States Air Force
Written to help executives determine right from wrong during a Lean initiative, this lively work shows that Lean is more about an approach than it is about tools. It presents the successful strategies and case histories of several key American leaders who have been instrumental in bringing Lean to the forefront of various industries. Catalog no. PP7382, 2009, 162 pp., ISBN: 978-1-56327-382-7, $39.95 / £24.99
Simple Excellence Organizing and Aligning the Management Team in a Lean Transformation Adam Zak and Bill Waddell This book explains the critical role that each member of the senior management team must play in achieving a company’s transformation to a Lean organization. It charts a course of simplification, in contrast to the complications that pervade traditional management by functional silos, and also the increasing complexity of managing popular improvement initiatives such as Lean, Six Sigma, and Theory of Constraints. Written by well-known authorities, the book includes case studies from companies recognized for excellence. This is the first book to spell out in detail the role of each key individual on the management team, including sales and marketing, human resources, purchasing/supply chain, information technology, finance, and engineering. Catalog no. K11744, November 2010, c. 152 pp., ISBN: 978-1-4398-3845-7, $39.95 / £25.99
Quality Management Theory and Application Peter D. Mauch Quality is not an engineering discipline, but a business practice. Peter Mauch offers his expertise in this groundbreaking book, demonstrating the necessity of considering quality as a sustained management activity. Divided into five sections, the book covers staffing, motivation, control, planning, and organization. It offers quality management practices and discusses the impact of managing for quality throughout an organization. The book addresses the alignment of individual departments to maximize quality, business planning and success metrics, record keeping, and department level quality control implementation. Catalog no. K10712, January 2010, 171 pp., ISBN: 978-1-4398-1380-5, $49.95 / £31.99
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STRATEGY It's About Time The Competitive Advantage of Quick Response Manufacturing Rajan Suri Presenting the developments in QRM since the publication of Rajan Suri’s landmark text, Quick Response Manufacturing, this book illustrates how QRM can not only reduce lead times but also improve quality, reduce operating costs, and enable companies to gain a substantial market share. It explains how factories in advanced nations can use QRM strategy to compete with manufacturers in low-wage countries and provides helpful pointers for QRM implementation, including accounting strategies, novel cost-justification approaches, and a stepwise process for implementation. It also includes a CD with time-saving tips to help you work through implementation issues—including simple calculation methods and tools to support the design of your QRM strategy. Catalog no. K10299, March 2010, 228 pp., ISBN: 978-1-4398-0595-4, $39.95 / £25.99
Flexibility Flexible Companies for the Uncertain World Gill Eapen “For your company or your career, Flexibility is a worthwhile guide to problem solving and decisiveness amid the uncertainty. — Martin Mackay, President, PharmaTherapeutics Research and Development
In an information and knowledge-driven environment with high levels of uncertainty, most traditional ideas of structure, system, and strategy are ineffective. This book shows how to create, maintain, and accelerate an organization in a highly uncertain environment using flexibility. It analyzes the organization holistically and details its primary components independently. The author presents an economic framework of decision options to diagnose existing flexibility problems and provides guidance on how to improve flexibility and reduce risk. Catalog no. K10839, January 2010, 192 pp., ISBN: 978-1-4398-1632-5, $59.95 / £38.99
Listening to the Voice of the Market How to Increase Market Share and Satisfy Current Customers R. Eric Reidenbach Unique in its approach, this book focuses on the voice of the market (VOM) instead of the much more limiting voice of the customer (VOC). While the VOC typically refers to what the organization’s customers say, feel, or need, the voice of the market focuses not only on the needs of its customers, but also on those belonging to customers across other organizations in addition to one’s own. By focusing on the VOM, organizations can empower Six Sigma and Lean initiatives with a source of information that expands one’s view of the marketplace, which can be self-fulfilling in its limitation. Catalog no. PP9330, January 2010, 205 pp., ISBN: 978-1-4200-9330-8, $54.95 / £34.99
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STRATEGY Compression Meeting the Challenges of Sustainability Through Vigorous Learning Enterprises Robert W. Hall "Strategic leaders should not labor under the misconception that they will learn by reading this book. It is through using what they read that the real and important learning will occur." — John (Jack) Ward, former CEO, Gabor International
"Learning how to survive in this new Era of Sustainability will require a new way of thinking and working ... .” — Glenn Marshall, Northrop Grumman Shipbuilding, Benchmarking & Sustainability Champion
Global crises are squeezing us from all directions and with or without our participation, change will occur. To implement the sort of changes that will allow civilization to prevail rather than merely endure requires a resourcefulness and ingenuity beyond any the world has ever employed. In this volume, Doc Hall shows us how to learn to learn more effectively both as individuals and organizations, and in terms of processes. He invites us to rethink our perpetual devotion to old ideals and welcome the shift in thinking that must be our first and immediate step. Visit the compression website at compression.org Catalog no. K10325, January 2010, 280 pp., ISBN: 978-1-4398-0654-8, $49.95 / £31.99
Green Intentions Creating a Green Value Stream to Compete and Win Brett Wills Developed by a plant manager who experienced the challenges to going green, Green Intentions shows how the green value stream provides a dynamic approach to making green improvements. It defines each of the seven green wastes, explains the overall green value stream process, demonstrates how to map your green value stream, and provides guidance on implementation. Its practical approach shows how to realize initial savings from green initiatives so as to gain the support and momentum needed to eliminate all green wastes, leading to environmental sustainability as well as substantial business benefits, including new customers, improved employee retention, and increased revenues. Catalog no. PP9617, January 2010, 296 pp., Soft Cover, ISBN: 978-1-4200-8961-5, $39.95 / £25.99
Understanding A3 Thinking A Critical Component of Toyota's PDCA Management System Durward K. Sobek II and Art Smalley The A3 report has proven to be a key tool In Toyota’s successful move toward organizational efficiency. The power of the A3 report, however, derives not from the report itself, but rather from the development of the dynamic culture required for the implementation of an A3 system. Winner of a 2009 Shingo Research and Professional Publication Prize, this manual highlights the deep learning and professional development that occurs through the A3 process. The authors show that the report is an especially effective tool when implemented in conjunction with a PDCA-based management philosophy. The book includes some very practical advice on how to write and review A3 reports. Catalog no. PP7360, 2008, 184 pp., ISBN: 978-1-56327-360-5, $41.95 / £26.99
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STRATEGY The Ultimate Improvement Cycle Maximizing Profits through the Integration of Lean, Six Sigma, and the Theory of Constraints Bob Sproull This text uniquely integrates Lean concepts, Six Sigma, and the Theory of Constraints into a combined business strategy aptly named the Ultimate Improvement Cycle (UIC). Unlike other systems, the UIC is all about economizing resources by focusing improvement efforts on those key leverage points that will prove most optimal, rather than diluting one’s efforts with an expensive across-the board-approach to improvement. The UIC is derived from Bob Sproull’s years of executive experience with the Toyota Production System and consulting work with several high profile companies. He shows you how to take advantage of the cyclical nature of improvement to implement change that is perpetually effective and requires no more resources than you have on hand. Catalog no. PP9034, 2009, 288 pp., ISBN: 978-1-4200-9034-5, $59.95 / £36.99
Using Hoshin Kanri to Improve the Value Stream Elizabeth A. Cudney "… provides a clear and concise view of how to best use hoshin kanri to drive improvement and realize the level of results organizations want and need. This book should be required reading for all business executives." — Karen Martin, author of The Kaizen Event Planner
While value stream mapping is now accepted as a tool for identifying waste, future state mapping presents greater challenges. Achieving the full implementation pictured in an enhanced future state map is far more complex than its development. Hoshin kanri can help. This method encourages employees to incorporate performance metrics to reach the root cause of problems before searching for solutions and teaches them how to promote the achievement of sustainable implementation. Though developed in Japan this technique is based on Deming’s classic PDCA (Plan-Do-Check-Act) improvement cycle. A number of Deming Prize winners credit hoshin kanri as being key to their business success. Catalog no. PP8423, 2009, 160 pp., Soft Cover, ISBN: 978-1-4200-8423-8, $49.95 / £30.99
Hoshin Kanri for the Lean Enterprise Developing Competitive Capabilities and Managing Profit Thomas L. Jackson "Tom Jackson's practical and valuable insights are rivaled only by the importance and benefits of applying Hoshin Kanri." — Jamie Flinchbaugh, co-author, The Hitchhiker's Guide to Lean
Winner of a Shingo Prize For Excellence In Manufacturing Research, this book facilitates an understanding of hoshin kanri as a grand design implemented through a system of team agreements. It defines an improved X-matrix that incorporates a scorecard for identifying improvement opportunities and converting them into bottom line results in terms that financial managers can support. Beyond theory, it demonstrates the mechanics of hoshin kanri to accelerate brand equity while initiating Lean manufacturing and Six Sigma improvements. Accompanying the text is a CD containing forms, meeting agendas, and examples of X-matrices that are applicable to marketing, design engineering, and manufacturing. Catalog no. PP7342, 2007, 224 pp., Soft Cover, ISBN: 978-1-56327-342-1, $55.95 / £35.99
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STRATEGY The Toyota Kaizen Continuum A Practical Guide to Implementing Lean John Stewart Written by an expert, who in his 18 years with Toyota moved from an entry level operational position to the executive ranks, this very practical book provides a firsthand account on how to implement the Toyota Production System (TPS) throughout an organization. It answers questions on how to get the process started and how to get senior management excited about embracing TPS. The author, who has overseen implementations in various environments and cultures, gives real knowledge supported with examples so as to equip readers with the ability to make immediate improvements in their areas of responsibility. Catalog no. K12059, February 2011, c. 180 pp., Soft Cover, ISBN: 978-1-4398-4604-9, $39.95 / £25.99
Progressive Kaizen The Key to Gaining a Global Competitive Advantage John W. Davis Designed to teach the reader how to fully maximize kaizen events, this book describes the four distinct types of kaizen and the specific purpose of each. It then demonstrates how kaizen can be used as a prominent strategy when implementing Lean. This includes developing a structured plan for kaizen and giving strong consideration for using employee incentives to motivate improvements at the individual job level. • Provides a detailed description of the various types of kaizen and how and when to use them in order to obtain the greatest return on the investment of critical resources • Outlines how to conduct each type of kaizen event, who should be involved as participants, and what the expected results should be • Explains how to incorporate a unique Waste Reduction Activity Process (WRAP) that drives kaizen down to the individual job level and encourages on-going participation • Teaches how to expand both the use and effectiveness of kaizen processes Catalog no. K12062, January 2011, c. 112 pp., Soft Cover, ISBN: 978-1-4398-4608-7, $39.95 / £25.99
20 Keys to Workplace Improvement Iwao Kobayashi "This is the first work I have read that sets a structure and framework for organizations to follow if they wish to revolutionize the workplace. Kobayashi has removed the mystery of how to accomplish major improvement in a business. His insight is true genius!" — John Sutter, VP of Manufacturing, National Rubber Company, Inc.
Kobayashi is considered a genius by those who have adopted his reorganization strategies. Through this volume, he has helped many manufacturing companies integrate several of the best improvement methods into a coordinated system for drastic and continual improvement that will lead to enhanced quality and productivity and fewer errors. This program provides the strategies necessary to achieve ambitious goals through a five-level scoring system. It provides criteria for the five-levels that will guide your company to world-class status. Two valuable case studies demonstrate effective use by both a Japanese company and an American manufacturer. Catalog no. PP7109, 1996, 312 pp., ISBN: 978-1-56327-109-0, $59.95 / £38.99
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METRICS The Basics of Performance Measurement Second Edition Jerry L. Harbour While every smart executive now knows that you can’t understand, manage, or improve what you don’t measure, it was Jerry Harbour who turned that adage into the science of performance measurement. Harbour provides a six-step method for developing a performance measurement system. He shows how to design performance measurement families and how to build hierarchies tailored to different levels within an organization. He also covers collection and distribution, as well as the value of performance measure displays. When you finish this book, you will be able to undertake performance measurement with new confidence. You will also come away knowing how to present your findings with an authority that will convince stakeholders of the importance and accuracy of your results. Catalog no. K10132, 2009, 102 pp., Soft Cover, ISBN: 978-1-4398-0249-6, $14.95 / £9.99
The Performance Paradox Understanding the Real Drivers that Critically Affect Outcomes Jerry L. Harbour A complement to Harbour’s, The Basics of Performance Measurement, this work empowers managers to establish protocols that will measure and improve the performance of their employees and ultimately, their businesses. Harbour begins with a conceptual overview of performance as a whole. He then explores practical implications, covering modeling, measuring, and improved performance. Augmented by 200 case studies, this work demonstrates how simple models can be of great benefit. By examining real-world examples of how abstract ideas can be concretely applied, this book explains how to transform any business or organization into a high-performance one where results are obtained, rather than imagined. Catalog no. PP7390, 2009, 192 pp., ISBN: 978-1-56327-390-2, $36.95 / £23.99
Applied Concept Mapping Theory, Techniques, and Case Studies in the Business Applications of Novakian Concept Mapping Edited by
Brian Moon, Robert R. Hoffman, Joseph Novak, and Alberto Canas Providing case studies in business applications, this book describes the theory and methods underlying Novakian concept mapping. Developed by Joseph Novak as an educational strategy, concept mapping has been applied with increasing frequency to problems in the workplace. Novakian concept maps differ from other diagrams by their morphology, content, and semantics. The advent of Cmap Tools, a knowledge modeling software kit that enables computer-based creation and sharing of Novakian concept maps, has encouraged a wide range of mapping applications. The text presents original work from the authors and other contributors who have applied concept mapping in various business environments, including consumer products, engineering/product development, defense, and healthcare. Catalog no. K11403, December 2010, c. 288 pp., ISBN: 978-1-4398-2860-1, $59.95 / £38.99
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METRICS Beyond the Balanced Scorecard Improving Business Intelligence with Analytics Mark Graham Brown "The Navy's carrier maintenance community continually improves their execution of highly complex aircraft carrier overhauls using Mr. Brown's metrics concepts to measure long-standing improvement efforts with 'cold, hard facts.' We rely on Mr. Brown's analytics as an integral part of our efforts." — Dr. Jerry Blanton, AMSEC, Co-Founder, Carrier Team One
Most companies use some form of a scorecard to measure performance; yet, research suggests that the typical scorecard is based on unsophisticated measurements, resulting in misleading data. This volume details the right metrics for evaluating those aspects of performance not accurately tracked by most companies and government organizations. Through the text, mangers and quality control leaders can learn how to objectively measure customer relationships, employee satisfaction, external business environments, and supplier performance, as well as strategy and financials. Catalog no. PP7346, 2007, 240 pp., ISBN: 978-1-56327-346-9, $39.95 / £24.99
Keeping Score Using the Right Metrics to Drive World Class Performance Mark Graham Brown "Insightful and appropriate for organizations needing a new approach to working smarter. The steps outlined for linking key success factors to performance measures help organizational leaders focus on measuring the right things the right way." — Marie E. Artale, Customer Satisfaction Manager, IBM Corporation
"… delivers comprehensive and easy-to-understand guidelines for the development or tune-up of an organization's measurement system. Written with the same user-friendly clarity of his popular book, Baldrige Award Winning Quality, Brown makes the overwhelming subject of measurement less intimidating through his step-by-step presentation." — Julie S. Mehta, Performance Consultant, U.S. Coast Guard
Taking a balanced Baldrige approach, this book shows how to evaluate current approaches to measurement and pinpoint false measurements. It covers the selection of financial metrics, ways to measure employee and customer satisfaction, and methods to track performance and measure quality. Catalog no. PP7355, 2007, 224 pp., Soft Cover, ISBN: 978-1-56327-355-1, $28.95 / £17.99
The Pocket Guide to the Baldrige Award Criteria 15th Edition (5-Pack) Mark Graham Brown The Baldrige criteria are being used by thousands of organizations around the world to evaluate their progress toward becoming the best in their fields. This guide provides the answers to the questions most commonly asked about the award and the criteria. It also provides a brief explanation of each of the 18 items in the Baldrige criteria and lists the characteristics of organizations that excel in each of these 18 items. Catalog no. K10729, 2009, 64 pp., Soft Cover, ISBN: 978-1-4398-1423-9, $35.00 / £21.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Lean Hospitals Improving Quality, Patient Safety, and Employee Satisfaction Mark Graban “The concepts outlined in this book are the most powerful tools that I have ever encountered to foster innovation, ownership, and accountability at the frontline staff level. This is a must-read for any leader in today’s increasingly complex healthcare industry.” — Brett Lee, PhD, FACHE, Vice President, Children’s Medical Center, Dallas
Winner of a Shingo Research and Professional Publication Prize, this book has received universal acclaim from industry insiders as well as reform advocates. Drawing on his years of working with hospitals, Graban explains why and how Lean can be used to improve safety, quality, and efficiency in a healthcare setting. After highlighting the benefits of Lean for patients, employees, physicians, and the hospital itself, he explains how Lean manufacturing staples such as value stream mapping and process observation can help hospital personnel identify and eliminate waste in their processes, effectively preventing delays for patients, reducing wasted motion for caregivers, and improving quality of care. Catalog no. PP3805, 2009, 280 pp., Soft Cover, ISBN: 978-1-4200-8380-4, $47.95 / £29.99
Leading the Lean Healthcare Journey Driving Culture Change to Increase Value Joan Wellman, Pat Hagan, and Howard Jeffries Seattle Children's Hospital, Washington
Blending actual situations with practical theory, this book uniquely describes how the healthcare value proposition can be changed by reducing waste, variation, and complexity in healthcare. It reveals the leadership tenacity and culture change required to remove waste from healthcare processes and eliminate the root cause of soaring costs, poor quality, poor safety, and limited access. It provides practical, applicable advice alongside personal and organizational stories and case studies told by physicians and administrative leaders who are students of the Toyota Production System. Catalog no. K11406, December 2010, c. 303 pp., Soft Cover, ISBN: 978-1-4398-2865-6, $59.95 / £38.99
Transforming Healthcare Virginia Mason Medical Center’s Pursuit of the Perfect Patient Experience Charles Kenney A chronicle of one of the most unique and impressive events in United States healthcare, this book tells the story of a group of clinicians, administrators, frontline workers, trustees, and leaders, who blessed with vision, courage, and a relentless determination to improve, worked together to make their medical center into an example of efficiency and quality. Ultimately, it provides a new and possibly better way to approach the healthcare delivery challenge, as it demonstrates that we don’t have to compromise on quality of care to achieve cost control. Also check out 5S for Healthcare on page 25 by the consulting group responsible for the Virginia Mason plan. Catalog no. PP7375, November 2010, c. 224 pp., ISBN: 978-1-56327-375-9, $39.95 / £25.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Optimizing Emergency Department Throughput Operations Management Solutions for Health Care Decision Makers John M. Shiver and David Eitel “… gives the healthcare manager the tools needed to enhance the function of the Emergency Department …. The text is clear, concise and understandable to those lacking a technical background but who still want to apply fairly sophisticated techniques to improving the patient experience and the productivity of ED staff.” — J. Knox Singleton, President and CEO, Inova Health System
This landmark book provides senior-level emergency department (ED) managers and administrators with essential tools to make their job easier in the wake of a national crisis in ED capacity. It illustrates how information technology can play an important role in improving the performance of the ED. It also demonstrates how to improve financial performance, specialty services, and billing and collections functions. Because there are so many unpredictable elements related to the emergency room environment, this text explains how to predict patient volumes, flow, and space needs, using historical data to best plan for the unknowns. Catalog no. PP3775, January 2010, 260 pp., Soft Cover, ISBN: 978-1-4200-8377-4, $69.95 / £44.99
The Definitive Guide to Emergency Department Operational Improvement Employing Lean Principles with Current ED Best Practices to Create the “No Wait” Department Joseph T. Crane and Charles E. Noon Emergency departments were never designed to be the walk-in clinics they have become; yet, with so many having nowhere else to turn for care, ED’s have become cauldrons of resentment in which neither the best needs of patient or hospital are served. Offering a solution to this fiscal and medical madness, this step-by-step guide shows how the application of Lean principles can lead to more efficient, costeffective, and patient friendly departments. It brings together leading experts who demonstrate the unique application of Lean tools and concepts to hospital operations and looks at those hospitals that have put this innovative approach into action. Catalog no. K10415, January 2011, c. 352 pp., Soft Cover, ISBN: 978-1-4398-0840-5, $89.95 / £57.99
Discharge Planning Handbook for Healthcare Top 10 Secrets to Unlocking a New Revenue Pipeline Ali Birjandi and Lisa M. Bragg Hidden opportunities to improve profits in the healthcare industry abound in the area of discharge planning. Based on 25 years of experience, Birjandi and Bragg show hospital administrators and directors how they can tap into new revenue using the Six Sigma DMAIC model (Define, Measure, Analyze, Improve, and Control). The book includes a comprehensive case study, as well as a spreadsheet that can be used to track success. Its step-by-step implementation strategy highlights these five concepts: • Redefine discharge planning • Focus on the right metrics • Use lean concepts for redesign • Use a practical approach for improvement • Create a culture that produces results Catalog no. PP7392, 2009, 208 pp., Soft Cover, ISBN: 978-1-56327-392-6, $62.95 / £40.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Applying Lean in Healthcare A Collection of International Case Studies Edited by
Joe Aherne and John Whelton “For organizations looking for ideas as they embark on their Lean journey, these case studies provide wonderful examples and an opportunity to take a glimpse into the many possibilities of Lean.” — Colleen Kennedy MLIS, MHA, Leader Physician Engagement, British Columbia, Canada
“.. a must buy for any healthcare professional interested in delivering improvement opportunities.” — Eamon Counihan, Quality Co-ordinator, Bon Secours Health System, Ireland
Covering healthcare from clinical to nutritional services, this book provides a collection of international case studies that demonstrate how Lean thinking can be applied in the healthcare industry. Offering an international perspective, the text introduces key concepts of Lean healthcare and presents real-life examples to illustrate the practical benefits, such as increased patient satisfaction, and cost savings, that can result from a Lean philosophy. The book features a number of expert contributors who offer practical tips. It also includes a foreword from eminent psychiatry professor Jeffrey Clotheir, MD. Catalog no. K11351, April 2010, 247 pp., ISBN: 978-1-4398-2739-0, $49.95 / £31.99
The Pittsburgh Way to Efficient Healthcare Improving Patient Care Using Toyota Based Methods Naida Grunden "Every person who cares about modernizing health in America should read this book. If we could understand the Toyota system in health we would save thousands of lives and billions of dollars." — Newt Gingrich, Former House Speaker, Founder, Center for Health Transformation
“At a time when we are overwhelmed by the staggering evidence that health care systems that we depend on often fail us, here is a book that captures the power of real transformation.” — Frank Christopher, PBS producer of the series “Remaking American Medicine.”
Grunden provides a look at how principles borrowed from industry—in specific Toyota’s concept of Lean manufacturing—can be applied to make healthcare safer, as well as more effective and less costly. She compiles case studies from units in different hospitals around the Pittsburgh region that successfully applied industrial principles to the benefit of patients and the satisfaction of employees. This book has received rave reviews from a large number of public policy and health experts. Catalog no. PP7367, 2008, 224 pp., ISBN: 978-1-56327-367-4, $41.95 / £26.99
Comprehensive Healthcare for the U.S. An Idealized Model William F. Roth Award-winning author Roth solicits the contributions of health workers from around the globe to examine the mire of technical quality and inefficient delivery that has become the U.S. healthcare system. He looks at various challenges, discussing how these are dealt with by 12 nations, all of which, according to WHO, rank higher than the U.S. in terms of services provided. Roth draws from the best to design an idealized model for healthcare that would fit this country's unique requirements. Researched and referenced to satisfy policy professionals and administrators, the book is lucidly written to engage all stakeholders with a fresh understanding of what is valuable and viable. Catalog no. K11453, January 2010, 174 pp., ISBN: 978-1-4398-2955-4, $49.95 / £31.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE 5S for Healthcare J. Michael Rona Consulting Group LLC Series: Lean Tools for Healthcare Series
Based on Hiroyuki Hirano's classic 5 Pillars of the Visual Workplace and modeled after the Shingo Prize-winning Shopfloor Series for Lean Manufacturers, this work adopts a proven reader-friendly format to impart all the information needed to understand and efficiently implement Lean methodology in a healthcare setting. Written by the principals involved with the Rona Consulting Group, who were responsible for the groundbreaking implementation of the Toyota Production System at the Virginia Mason Medical Center, it provides a wealth of transferable examples along with a step-by-step hands-on guide that will demonstrate how to get an entire organization positively involved in the process. Catalog no. K10196, January 2010, 120 pp., Soft Cover, ISBN: 978-1-4398-0350-9, $28.95 / £18.99
Value Stream Mapping for Healthcare Made Easy Cindy Jimmerson "… an invaluable resource for all involved in implementation of Lean in Healthcare. … Jimmerson has demystified the value stream map and made it an actionable tool for all!" — Mimi Falbo, Mimi Falbo LLC
"I would highly recommend this book to anyone desiring to genuinely adopt the Toyota approach to the healthcare industry and to do so with confidence. This is the real deal." — Ken Pilone, President, Sterling Methods Consulting Group, LLC
This manual introduces readers to the simple but essential Value Stream Map (VSM). It offers an easy-to-learn introduction to VSMs that will enable readers to look at any process with different eyes. The book also highlights simple to use data collection and interpretation as part of the VSM process. Catalog no. PP7852, January 2010, 119 pp., Soft Cover, ISBN: 978-1-4200-7852-7, $54.95 / £34.99
Kaizen for Lean Healthcare Thomas L. Jackson Series: Lean Tools for Healthcare Series
This user-friendly book, written by a member of the J. Michael Rona Consulting Group, is designed to improve understanding of kaizen as it applies to healthcare settings. It describes what a kaizen event is and explains all the phases necessary to learning and implementing continuous improvement practices by a group of individuals to a targeted area within a specified time period. It also outlines how to prepare a presentation and circulate and display results using Lean implementations. This text aids in the understanding of concepts and theories through the use of margin notes that reveal important information, key terms and points, healthcare examples, and how to steps. Catalog no. K11931, June 2011, c. 120 pp., Soft Cover, ISBN: 978-1-4398-4152-5, $28.95 / £18.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE A3 Problem Solving for Healthcare A Practical Method for Eliminating Waste Cindy Jimmerson "What a great book to address a huge gap in healthcare process improvement! Having a source book to teach continuous change and illustrate waste reduction based on the Toyota Production System to busy healthcare practitioners has been sorely lacking until now. I have used the A3 in my hospital and it works! Clinical workers can see the entire project on one piece of paper as well as areas of obvious waste." —James Nesbitt, MD, MMM, Project Manager, Providence Alaska Medical Center
Written by an expert in Lean principles, this book offers an easy-to-use problemsolving method that can be applied to every aspect of healthcare to identify, understand, and improve processes. Illustrated with numerous A3s in various stages of development, this practical, easy-to-use workbook explains how to extend the value stream mapping philosophy to the more focused perspective of the single page A3 report. Catalog no. PP7358, 2007, 176 pp., Soft Cover, ISBN: 978-1-56327-358-2, $57.95 / £36.99
Leveraging Lean in Healthcare Transforming Your Enterprise into a High Quality Patient Care Delivery System Charlie Protzman, George Mayzell, and Joyce Kerpchar Expanding on the concepts and tools of Lean hospitals and coupling these ideas with the principles of Six Sigma, this book presents a how-to guide to true efficiency in hospitals. Beginning with an overview and description of Lean tools, such as Toyota and Gilbreth and Taylor, it demonstrates Lean implementation at every level of a hospital including the ED, OR, Radiology, and Cath Lab. The authors discuss traditional methods and typical problems, look at a value stream map for each area, and provide actionable blueprints and case studies to facilitate Lean improvements. Catalog no. K10715, November 2010, c. 422 pp., Soft Cover, ISBN: 978-1-4398-1385-0, $74.95 / £47.99
Essentials for the Improvement of Healthcare Using Lean & Six Sigma D.H. Stamatis By using theories of Six Sigma and Lean methodology, this text presents solutions to fundamental problems in healthcare. This text breaks the system down into three fundamental areas: primary care, hospitals, and managed care. The author identifies the four critical issues that affect healthcare as it relates to efficiency and cost by addressing the specific issues. The book discusses the application of IT in healthcare as a tool of improvement, and how to select the best project for improvement. The author also includes a discussion of ISO and the Malcolm Baldrige award. Case studies are included to illustrate successes. Catalog no. K12058, December 2010, c. 444 pp., ISBN: 978-1-4398-4601-8, $79.95 / £49.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Safer Hospital Care Strategies for Continuous Innovation Dev Raheja An examination of the effectiveness of present hospital care methods, this book illustrates how to find simple, comprehensive solutions that produce high return on investment. It emphasizes innovative techniques, proven safety methods, models for risk managers, heuristics for leading change, reliability methods that deliver right care over time, dangers in medical devices for critical care, and techniques for giving care with speed and efficiency without compromising safety. Experts from the aviation industry, world-class organizations such as Toyota and General Electric, and innovative hospitals such as Johns Hopkins offer their insight. Catalog no. K11114, December 2010, c. 200 pp., Soft Cover, ISBN: 978-1-4398-2102-2, $59.95 / £38.99
Medical Error and Harm Understanding, Prevention, and Control Milos Jenicek Presenting the work of long time physician and teacher, this book provides a thorough investigation into medical error. It presents a short history of error in general across various domains of human activity, and then explores approaches used to investigate and ameliorate errors in medicine and other health sciences. The book also discusses whether dealing with errors is a learned skill and looks at how much of the problem with medical error is caused by the medical community’s failure to teach and understand everything there is to know about medical error, including the often neglected importance of critical thinking skills.It also considers the physician’s growing role in tort litigation. Catalog no. K11671, July 2010, 384 pp., ISBN: 978-1-4398-3694-1, $79.95 / £49.99
Performance Based Medicine Creating the High Performance Network to Optimize Managed Care Relationships William J. DeMarco Highlighting quality driven issues and the power behind pay for performance and value-based benefit designs, this book provides the knowledge to establish performance based structures, such as quality measurement, incentive payment structure, and incentive size, within an existing organization. Focusing on how to implement new designs and how to create strategies to measure performance and improve efficiency, it discusses how to create value and optimize payment and market share. It also describes the trade off of systems and IT investments by providers and payers to gain incremental quality improvement. Catalog no. K10654, January 2011, c. 300 pp., ISBN: 978-1-4398-1288-4, $69.95 / £44.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Health Care Will Not Reform Itself A User's Guide to Refocusing and Reforming American Health Care George C. Halvorson "Students of health reform would do well to consider this book as an invaluable text for our national public policy debate." — Tom Daschle, Former U.S. Senate Majority Leader
"This hard hitting and practical blueprint for reforming medicine will work if we listen. I even took notes." — Dr. Mehmet Oz, Vice Chair and Professor of Surgery, Columbia University; Oprah Radio
Written by the CEO of the largest healthcare provider in the nation, this book provides a basic primer on the American health care system. Making use of insightful anecdotes and examples, Halvorson cuts through the rhetoric to offer a blueprint for achieving real improvements in health care delivery. He explains how health insurance works in the U.S. compared with the rest of the world and outlines the barriers to American reform. Catalog no. K10830, 2009, 184 pp., ISBN: 978-1-4398-1614-1, $29.95 / £19.99
Healthcare Transformation A Guide for the Hospital Board Member Maulik Joshi and Bernard Horak "This book is a ‘must-read’ resource for Hospital Management Teams and Board members. The content is supported by extensive knowledge and practical current experience of the authors." — Alexander (Rusty) Sloan, MD, MACP, Lt. General, USAF, Retired
Designed for easy reference by people with busy schedules, this concise manual provides hospital board members and executives with practical guidance on how to become actively engaged in the transformation of their organization. It focuses on how the healthcare industry as a whole is transforming and stresses the importance of having board members who are able to provide leadership. The manual is ideal for orienting new board members and for providing experienced members with insight on key issues. It supplies questions to ask stakeholders that will facilitate engagement. Each chapter is organized around action steps designed to build organizational quality and facilitate change. Catalog no. K10283, 2009, 128 pp., Soft Cover, ISBN: 978-1-4398-0506-0, $39.95 / £24.99
Governance for Health Care Providers The Call to Leadership Edited by
David B. Nash, William J. Oetgen, and Valerie P. Pracilio "… essential reading for all physicians who are about to embark on the journey of governance. I for sure will recommend this book to the physicians on my hospital board." — ACMQ Focus
Physicians, nurses, pharmacists, and other medical professionals who serve on the boards of private, nonprofit institutions often do so with much more diligence than knowledge. Very little material exists to cover the range of issues that are so vital at a time when health care institutions face patient overloads and budget shortages. Written by leading health care advocates and authorities, this volume provides a readily accessible resource that helps define the functions of a board member and summarizes the problems that they most likely will face including finance and compliance issues, as well as funding and strategic planning. Catalog no. PP7853, 2009, 344 pp., ISBN: 978-1-4200-7853-4, $83.95 / £52.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Healthcare Delivery in the U.S.A. An Introduction Margaret F. Schulte “This book would be helpful for those early in their careers or transitioning in from other industries to help improve quality and processes. I certainly wish I had this guide when I was starting in healthcare.” — Mark Graban, Senior Lean Consultant, ValuMetrix Services, Ortho Clinical Diagnostics, Inc., Author of Lean Hospitals
The position of the medical sector as a growth market is opening new avenues for workers outside the traditional realm of healthcare, such as management engineers, IT professionals, and process improvement specialists. A guide for healthcare market entrants, this book equips new hires with the knowledge needed to navigate the business of medicine. It also provides a much-needed orientation to the broader healthcare work environment for those working in hospitals or as vendors and manufacturers. The author, editor of the American College of Health Executive’s Frontiers in Health Services Management, confronts challenges facing the industry as a whole, including finance, legal, regulatory, and workforce issues. Catalog no. PP8493, January 2010, 144 pp., Soft Cover, ISBN: 978-1-4200-8493-1, $49.95 / £25.99
Successful Collaboration in Healthcare A Guide for Physicians, Nurses and Clinical Documentation Specialists Colleen M. Stukenberg “Colleen is a recognized expert in the field of Clinical Documentation Improvement. Anyone interested in implementing a successful Clinical Documentation Improvement Program should read this book before starting the process." — Lynne Spryszak, RN, CCDS, CPC-A, Manager, Precyse Solutions, LLC
A guide for healthcare providers to forge alliances that will improve patient care, this book describes ways in which nurses and physicians can collaborate to enhance safety, quality, and treatment efficacy, and how this collaboration can have positive financial effects. It demonstrates how cooperation can meet the changing requirements of governing bodies and government regulations as well as technological advancements. It addresses the roles of direct patient caregiver, charge or team leader nurse, case manager, and clinical documentation specialist, and covers regulatory and financial topics such as Recovery Audit Contractors (RAC) and Pay for Performance. Catalog no. K10656, January 2010, 136 pp., ISBN: 978-1-4398-1292-1, $59.95 / £38.99
Paradox and Imperatives in Health Care How Efficiency, Effectiveness, and E-Transformation Can Conquer Waste and Optimize Quality Jeffrey C. Bauer and Mark Hagland “... puts the health care industry’s biggest challenges into a fresh and useful perspective. ... Through numerous case studies, the authors show how successful health care organizations are using performance-improvement tools to produce top-quality services as inexpensively as possible.” — QualityDigest
In this groundbreaking critically acclaimed collaboration, Bauer and Hagland explain why providers must draw upon internal resources to increase net revenue and provide the quality of care that payers and consumers are demanding. Through numerous case studies, the authors show how pioneering health care organizations are using performance improvement tools— including Lean management, Six Sigma, and the Toyota Production System—to produce excellent services as inexpensively as possible. This book challenges health care leaders to change their status quo mentality and to put their organizations on a positive path… while redirection is still possible. Catalog no. PP7379, 2008, 192 pp., ISBN: 978-1-56327-379-7, $41.95 / £26.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Dynamic Capacity Management for Hospitals Advanced Methods and Tools for Optimization Pierce Story Presenting new approaches, tools, and perspectives, this book facilitates the effective management of the complexities and dynamism unique to health care operations. It introduces health care managers and professionals to state-of-the-art concepts designed to improve both process- and dynamic systems-focused performance and develop appropriately dynamic process-level solutions to complex systems level issues. Employing common methodologies such as Lean, Six Sigma, and CQI, the "Dynamic Capacity Management" approach addresses the analysis and improvement of hospital- and department-wide capacity, patient flow, resource allocation, and performance optimization. Catalog no. K11039, November 2010, c. 235 pp., ISBN: 978-1-4398-1975-3, $59.95 / £38.99
The Medicare Recovery Audit Contractor Program A Survival Guide for Healthcare Providers Duane C. Abbey Written by medical billing guru, Duane Abbey, this volume explains all that is required to prepare and successfully defend against RAC audit recoveries. Using the same succinct style that always makes his writing so accessible, Abbey illustrates his lessons with simple case studies placed in the context of a fictitious community whose population is served by a hospital, clinics, a nursing facility, and other providers all seeking to maintain compliance and profitability. In discussing RAC guidelines, this resource — • Shows how to identify overpayment areas and associated compliance issues • Addresses resource requirements including new personnel, such as RAC specialists • Includes planning models for developing compliance departments • Provides an extensive glossary to make sense of medical billing’s alphabet soup of acronyms Catalog no. K11113, February 2010, 124 pp., Soft Cover, ISBN: 978-1-4398-2100-8, $59.95 / £38.99
Healthcare Payment Systems Fee Schedule Payment System Duane C. Abbey Following Healthcare Payment Systems: An Introduction, this second volume in a series by medical payment expert Duane Abbey provides an overview and discussion of the various fee schedule payment systems used by healthcare providers and third party payers. Designed for hands-on use by providers and their fiscal agents, emphasis is placed on the basic elements of any fee schedule payment system along with the myriad variations that exist to garner payment for physician services, ambulance services, durable medical equipment, prosthetic and orthotics, laboratory services, physical and occupational therapy and associated services, and/or medical products. This volume offers special attention to the Medicare Physician Fee Schedule. Catalog no. K11862, October 2010, c. 144 pp., Soft Cover, ISBN: 978-1-4398-4023-8, $59.95 / £38.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE The Physician Employment Contract Handbook Second Edition A Guide to Structuring Equitable Arrangments Maria Todd This revised and updated edition provides an invaluable resource for physicians who are looking to sell their practice and for health systems who wish to become affiliated with a group practice or who are interested in contracting with physicians. The book provides sample physician employment contracts and explains how each contract works. Written by an expert in the field of physician contracting, the text discusses the various legal and compliance issues related to physician employment, such as anti-self referral and anti-kickback issues, and examines how to resolve disputes through arbitration or mediation. The author also outlines the pros and cons of various partnership arrangements. Catalog no. K10674, March 2011, c. 275 pp., Soft Cover, ISBN: 978-1-4398-1316-4, $89.95 / £57.99
Workplace Clinics and Employer Managed Healthcare A Catalyst for Cost Savings and Improved Productivity A. Michael La Penna The advent of organizations considering an on-site approach to the delivery of healthcare services increases in direct proportion to the rising of healthcare costs. This volume is a how-to manual on the design and implementation of an on-site program and presents the challenges and benefits of such a system. Topics discussed include hospital and specialty contracting; employee choice concerns; costcontrol; ancillary services such as pharmacy, lab testing, physical therapy, and imaging; workers compensation issues; benefits consultants; quality vs. value analysis; and other considerations. A case study is provided that follows the implementation of a program from inception to introduction. Catalog no. PP2448, January 2010, 278 pp., Soft Cover, ISBN: 978-1-4200-9244-8, $54.95 / £34.99
Transformative Quality The Emerging Revolution in Health Care Performance Mark Hagland Looking for ways to improve quality and cut costs, healthcare organizations are in the midst of overhauling all of their operational systems, as they seek to achieve heightened levels of quality. After providing a historical perspective and an analysis of the changing demands and demographics behind this current push, noted healthcare write Mark Hagland provides a thorough look at in-depth case studies involving dramatic transformations in health delivery systems of varying complexity. Hagland also looks at the role of information technology in these transformations and discusses likely outcomes and future trends. Catalog no. PP8492, 2009, 174 pp., ISBN: 978-1-4200-8492-4, $52.95 / £33.99
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INDUSTRIES / FUNCTIONS – HEALTHCARE Consumer Directed Health Care A 360 Degree View Kim Slocum “…a top-notch synthesis of credible research on health care in the United States. … It is a must-read and a call to action for persons in policy and leadership positions in and out of health care and for anyone who wants to make sense of the complex dilemma in which US health care finds itself.” —Margaret F. Schulte, DBA, FACHE, Editor, Frontiers of Health Services Management
Drawing from three decades of experience in a variety of healthcare, pharmaceutical, and biotechnology firms, respected healthcare consultant, Kim Slocum applies a uniquely broad viewpoint to the U.S. healthcare crisis. He discusses how the system has evolved and debunks various myths that continue to persist. Exploring potential solutions, he balances many diverse and conflicting factors, including the movement to make healthcare more patient-centered and the growing trend to transfer significant portions of financial risk to patients via high-deductibles. Slocum closes the book by discussing what a successful consumer-directed system might look like and what steps would be required to make it happen. Catalog no. PP7391, 2009, 160 pp., Soft Cover, ISBN: 978-1-56327-391-9, $57.95 / £36.99
Statistical Analysis for Decision Makers in Healthcare Second Edition Understanding and Evaluating Critical Information in Changing Times Jeffrey C. Bauer Designed for the busy healthcare professional who needs to collect, analyze, and/or evaluate data, this readily accessible work explains the fundamental concepts, uses, and misuses of statistics. Without jargon or mathematical formulas, the author introduces the practice of quantitative analysis to provide an understanding of the principles of scientific inquiry, applied to clinical medicine, program evaluation, policy analysis, management, accounting, and research. The book discusses practical scientific methods to show why statistics cannot compensate for bad science or bad data. It will help readers to intelligently evaluate the many numbers that cross their desk in the normal course of business. Catalog no. K10061, 2009, 160 pp., Soft Cover, ISBN: 978-1-4398-0076-8, $49.95 / £30.99
Pursuing Excellence in Healthcare Preserving America's Academic Medical Centers Arthur M. Feldman "… a terrific resource for anyone interested in understanding the indispensable role of the academic health center. … Dr. Feldman identifies the key problems we need to solve and the kinds of solutions we must adopt to ensure the excellence of our essential missions in research, training, and health care going forward. A book all health care leaders should read and then read again." — Michael M.E. Johns, MD, Chancellor, Emory University
For over 100 years, academic medical centers (AMCs) have been the bastion of medicine; providing outstanding care, incubating the discoveries that have improved healthcare around the world, and training the next generation of doctors and scientists. Delineating the issues that have lead to the current crisis in AMCs, this book presents an in depth analysis of the issues and challenges facing AMCs and offers recommendations that allow them to achieve their core mission — the delivery of outstanding patient care. Catalog no. K10852, January 2010, c. 336 pp., ISBN: 978-1-4398-1657-8, $49.95 / £31.99
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INDUSTRIES / FUNCTIONS – OFFICE Lean Office and Service Simplified The Definitive How-To Guide Drew Locher A comprehensive reference, this unique book covers all of the relevant concepts pertaining to the coinciding realms of value stream mapping and the Lean office. Providing extensive detail regarding the application of Lean thinking to office and services, this book describes value stream management, standard work, flow, and pull. It defines specific how-to methodologies in exhaustive depth, breaks down key Lean concepts into their elementary components and describes them in the context of office and services, provides implementation strategies on a function-byfunction or department-by-department basis, and includes detailed examples throughout. Catalog no. K11073, January 2011, c. 136 pp., ISBN: 978-1-4398-2031-5, $39.95 / £25.99
Lean Human Resources Redesigning HR Processes for a Culture of Continuous Improvement Cheryl M. Jekiel “Jekiel makes a strong case for the greater part of waste coming from poor or nonexistent HR systems; … Her systematic mapping of the path to get out of the cave and into the light of day gives the reader hope that transformation of the culture is possible.” — Sherrie Ford, Chairman, Executive VP, Culture Power Partners, Inc.
Ultimately, lasting change requires evolution in organizational cultural and to achieve such change requires definitive changes in behavior. Jekiel, who has been implementing Lean initiatives out of HR offices for 20 years, puts forth a proven five-year plan that includes the building of improvement-linked competencies into each job. A unique approach to continual improvement, this volume offers companies the means to maximize employee potential by first showing them how to increase the improvement power of their HR departments. A final section is designed especially for CEOs who must address their own views of HR before addressing improvement. Catalog no. K10663, September 2010, 263 pp., Soft Cover, ISBN: 978-1-4398-1306-5, $39.95 / £25.99
Creating the Ultimate Lean Office A Zero-Waste Environment with Process Automation Raymond S. Louis All businesses are dependent on cost-incurring office and administrative processes. In Creating the Ultimate Lean Office, Raymond Louis takes the definition of waste a step further than one finds in Lean manufacturing. Louis defines any office activity, even if it adds value, as wasteful if it is manually performed when it can be cost-effectively automated. He calls the technique to eliminate manually performed activities administration automation. This technique encourages the design of automated processes to meet the needs of specific environments. This book, in the hands of an improvement team applying due diligence, will create a Lean office that can compete with the best organizations in the world. Catalog no. PP7371, 2008, 160 pp., Soft Cover, ISBN: 978-1-56327-371-1, $49.95 / £31.99
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INDUSTRIES / FUNCTIONS – OFFICE The Kaizen Event Planner Achieving Rapid Improvement in Office, Service, and Technical Environments Karen Martin and Mike Osterling "This book will be of great benefit to any leader in the planning of kaizen events … I plan to purchase a copy for each of our managers and Lean facilitators." — Chat Norvell, President and CEO, CarePartners
A practical how-to guide, this book takes readers through the ins and outs of planning and executing kaizen events in non-manufacturing settings and conducting post-event follow-up to sustain changes made. The authors provide methods and tools to help build a motivated workforce and lay a foundation for continuous improvement. Readers will learn how to effectively scope the activity, engage the right people, and facilitate events with measureable results. The clear, concise presentation allows beginners and experienced practitioners to venture into non-manufacturing environments with comfort and ease. An accompanying CD provides immediate access to a number of Excel-based tools. Catalog no. PP7351, 2008, 240 pp., Soft Cover, ISBN: 978-1-56327-351-3, $55.95 / £35.99
Metrics-Based Process Mapping An Excel-Based Solution Karen Martin and Mike Osterling Metrics-based Process Mapping (MBPM) is a process-design methodology that combines the cross-functional aspects of traditional swim-lane process maps with the key time and quality metrics incorporated within Value Stream Maps. Especially effective for analyzing and designing office, service, and technical processes, this CD contains an Excel-based tool to electronically archive and distribute current and future state MBPMs that have been created manually in a cross-functional team setting. The tool includes a custom toolbar to ease the mapping process and an autocalculation feature that compares current and future state process performance metrics. Easy to use with no installation necessary, the tool requires only basic Excel experience. It includes a detailed instruction guide that walks users through the process of creating a metricsbased process map. Catalog no. PP7380, 2009, CD-ROM, ISBN: 978-1-56327-380-3, $157.95 / £99.00
Flow in the Office Implementing and Sustaining Lean Improvements Carlos Venegas “Whether readers are interested in a specific topic, say kaizen, or have committed themselves to launching Lean in their workplaces, they will discover useful nuggets in Flow in the Office that help them combine their current thinking with the possibilities of what Lean can do for their businesses." — Sir Read A Lot
For years, Lean initiatives have generated staggering improvements on the shop floor. And now many business leaders want these Lean benefits incorporated into non-traditional environments. This book demonstrates how to efficiently translate and transition Lean manufacturing principles into any office. In this work, Carlos Venegas confirms that the competitive advantage will go to those who manage information most effectively and efficiently. It is not enough to be a Lean manufacturer; you need to be a Lean business. The author translates the language of Lean Manufacturing into the language of Lean Office Flow, bringing bits, bytes, and conversations into the concrete world of process improvement. Catalog no. PP7361, 2008, 144 pp., Soft Cover, ISBN: 978-1-56327-361-2, $36.95 / £23.99
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INDUSTRIES / FUNCTIONS – OFFICE 5S for the Office Organizing the Workplace to Eliminate Waste Thomas Fabrizio and Don Tapping "… more than a book about 5S in the office … encompasses a total facility-wide process of implementing and sustaining improvements that will last. … The checklist, and form examples are just what is needed to help your organization brainstorm what will work best in your environment." — Mary E. Murphy, Haldex Way Change Agent, Kansas City, Missouri
Fabrizio and Tapping bring the concepts of Hiroyuki Hirano’s 5S System into the office. The activities at the heart of this process include organizing, ordering, cleaning, standardizing, and their sustainment. More than a book about the office; this critically acclaimed work elaborates a total facility-wide process for implementing and sustaining improvements, while also demonstrating the importance of senior management’s participation. An accompanying CD contains computer-usable blank versions of forms and worksheets that appear in the book. Catalog no. PP7318, 2007, 192 pp., Soft Cover, ISBN: 978-1-56327-318-6, $49.95 / £31.99
The Complete Lean Enterprise Value Stream Mapping for Administrative and Office Processes Beau Keyte and Drew Locher "Keyte and Locher have provided a valuable contribution for identifying strategic operational value streams for administrative and office processes. They demonstrate that the next generation of waste identification and elimination is in the business support functions." — Dr. Ross E. Robson, Executive Director, Shingo Prize, Utah State University
Winner of a Shingo Prize for Excellence in Manufacturing Research, this manual offers a step-by-step approach to applying Lean initiatives to the administrative and office environment. Written for leaders looking to improve production support activities within their order-to-cash value stream, this volume provides a valuable tool for applying value stream mapping to non-production areas. It helps identify office wastes, establish performance metrics, and speed up administrative workflow, so as to improve office efficiency. Catalog no. PP7301, 2005, 160 pp., Soft Cover, ISBN: 978-1-56327-301-8, $49.95 / £31.99
Value Stream Management for the Lean Office Eight Steps to Planning, Mapping, & Sustaining Lean Improvements in Administrative Areas Don Tapping and Tom Shuker "We have been on our Lean journey in manufacturing for some time now, and are expanding that success … across administration for the entire company. … We purchased the Value Stream Management for the Lean Office workbook for all 900+ leaders. … These workbooks were an outstanding hit and I re-ordered several times to make sure everyone who needed one, received one!" — David Speer, Corporate Director, LeanSigma®, Maytag Corporation
Extending their eight-step process to the realization of a Lean office, Tapping and Shuker use a customer service case study to illustrate the effectiveness of the value stream storyboard. In addition to providing a thorough overview of basic Lean concepts, the book details methods for identifying administrative activities in need of attention. Includes a Lean assessment tool, a storyboard template, charts, a team charter, and worksheets Catalog no. PP7246, 2003, 176 pp., Soft Cover, ISBN: 978-1-56327-246-2, $49.95 / £31.99
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INDUSTRIES / FUNCTIONS – OFFICE Lean Six Sigma for the Office James William Martin Historically, the integration of manufacturing methodologies into the office environment has proven problematic. As a solution, Six Sigma guru James Martin presents proven modifications that can be properly deployed in offices, particularly those offices involved with global operations. Making use of kaizen and Six Sigma concepts, along with Lean manufacturing principles, he instructs managers on how they can improve operational efficiency and increase customer satisfaction. Utilizing summarizing tables and operational roadmaps, he demonstrates how simple and standardized processes can be adopted to improve efficiency and eliminate costly mistakes. Introduces Minitab® Quality Companion and Crystal Ball® Software Catalog no. AU6879, 2009, 348 pp., ISBN: 978-1-4200-6879-5, $52.95 / £33.99
Freedom from Command and Control Rethinking Management for Lean Service John Seddon "… John Seddon provides a key to the wise and the brave that can unlock their people, their customers and their profits. Do you have the faith, bravery and conviction to use it?" — Bruce MacLellan, Director, Customer Contact, Capital One
Proving that top-down decision-making within service-oriented businesses leads to managers who are detached from employees and daily operations, John Seddon demonstrates that decision-making based on purpose-related measures (such as putting customers first and improving services) can help managers reconnect with operations, see waste, and exploit opportunities for improvement. Through case material, this Toyota Production Systems adherent illustrates how systems thinking leads to improved service, revenues, and staff morale. He also posits that the service industry fundamentally differs from manufacturing, and shows how Toyota production principles can be applied in that arena. Catalog no. PP7327, 2006, 256 pp., ISBN: 978-1-56327-327-8, $49.95 / £31.99
Lean Administration Case Studies in Leadership and Improvement Edited by
Association for Manufacturing Excellence Responding to the growing interest in applying Lean to non-manufacturing operations, this first volume of the Enterprise Excellence Series covers the implementation of Lean in administrative and office applications. Drawing on case studies from AME’s Target Magazine, it provides a practical, in-depth description of Lean offices implementations, most of which have not been described in other publications. Offering real-world Lean office information, the case studies included are categorized into three areas: Leadership, Organization and Training; Improving Processes; and Lean in Healthcare. Catalog no. PP7366, 2007, 144 pp., Soft Cover, ISBN: 978-1-56327-366-7, $20.95 / £13.99
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INDUSTRIES / FUNCTIONS – OFFICE Lean Higher Education Increasing the Value and Performance of University Processes William K. Balzer "… a must read for all university administrators–it helps them build processes and services that truly serve students." — Tom Andrews, BGSU Firelands College
This book is designed to teach academic administrators how to apply Lean business principles to the successful running of their institutions. It returns education to the consumers it was designed to serve: the students. Applying voice of the customer (VOC) concepts, it introduces educators to Lean tools, such as value stream mapping. Relying on concepts inherent in all Lean processes, it focuses on involving stakeholders and holding them accountable for the delivery of quality every step of the way. Catalog no. K10754, April 2010, 312 pp., Soft Cover, ISBN: 978-1-4398-1465-9, $49.95 / £31.99
Lean for the Public Sector The Pursuit of Perfection in Government Services Bert Teeuwen Written specifically to address the application of Lean practices in government and the public sector, this highly original reference covers the basic philosophy of Lean before detailing specific methods to improve processes in the public sector. It addresses concerns unique to the public sector environment and considers the role of the citizen, not only as customer, but as a voter, taxpayer, and community participant. The approach provides a more reality-based view of value-added services and waste in the public sector. The text also includes many explanations of Lean principles and methods, examples, and international case studies. Catalog no. K11863, November 2010, c. 218 pp., Soft Cover, ISBN: 978-1-4398-4022-1, $29.95 / £19.95
Organizational Assessment and Improvement in the Public Sector Kathleen M. Immordino Series: ASPA Series in Public Administration and Public Policy
In order to implement an integrated cycle of assessment, planning, and improvement, government agencies need a framework for organizational assessment that speaks to their unique needs. This book provides those who manage or work in government with an understanding of and a methodology for assessment. The book introduces the assessment concept and its significance in public organizations. It then focuses on procedures and demonstrates how communication that results from an assessment process can create a widely accepted case for change. The text presents a model grounded in the Malcolm Baldrige National Quality criteria but adapted for the language and culture of government organizations. Catalog no. AU4208, January 2010, 248 pp., ISBN: 978-1-4200-8420-7, $59.95 / £38.99
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INDUSTRIES / FUNCTIONS – IT Lean IT Enabling and Sustaining Your Lean Transformation Steven C. Bell and Michael A. Orzen “There has never been a more critical time to improve how IT integrates with the global business enterprise. This book provides an unprecedented look at the role that Lean will play in making this revolutionary shift and the critical steps for sustained success.” — Steve Castellanos, Lean Enterprise Director; Nike, Inc.
To achieve and sustain a Lean transformation, organizations must effectively engage and leverage IT in all aspects of continuous improvement. This work examines how IT can better understand and serve the needs of the business; how the business can engage IT in continuous improvement activity; how IT can apply the tools and methods of Lean inwardly; and how to measure the results of these efforts. The authors provide diagrams and tables depicting methods, practical examples, and case studies. Catalog no. K10912, September 2010, 360 pp., ISBN: 978-1-4398-1756-8, $49.95 / £31.99
Far from the Factory Lean for the Information Age George Gonzalez-Rivas and Linus Larsson “It’s one thing to develop a concept. It’s another to make it sing. This is the hymnal.” — Dr. Don V. Steward, CEO, Problematics; inventor of DSM
“Excellent guidance for leaders and workers in office and project environments, and a 'must read' for CIOs everywhere.” — Julian Amey, Principal Fellow, Warwick University
If you employ knowledge workers who do most of their work with computers, then this book is for you. Quite simply, it's for any organization with a lot of Web DNA that wishes to cut costs, improve performance, and stay perpetually competitive. Catalog no. PP9456, September 2010, 325 pp., Soft Cover, ISBN: 978-1-4200-9456-5, $49.95 / £31.99
Thin Air How Wireless Technology Supports Lean Initiatives Dann Anthony Maurno and Louis Sirico “A must read for executives looking to optimize performance while automating traceability in outsourced supplier networks.” —Raj Saksena, President and CEO, Omnitrol Networks Inc.
Drawing on success stories from dozens of diverse companies, this hands-on resource discusses the application of a wide range of wireless technologies, including RFID, wireless sensor networks, real-time location systems, and GPS. It addresses the modernization of infrastructure, elimination of costly hardware and redundant equipment, and the provision of real-time visibility. Provides access to a Lean Wireless ROI Calculator you can use to factor in variables specific to your company so as to calculate possible savings Catalog no. K10242, April 2010, c. 251 pp., ISBN: 978-1-4398-0439-1, $59.95 / £38.99
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INDUSTRIES / FUNCTIONS – IT Lean Connections Making Information Flow Efficiently and Effectively Chris Harris and Rick Harris Employing a workbook format, this manual follows RNA Manufacturing, a fictional company, through its implementation of a comprehensive Lean production system. As the authors outline RNA’s methods and thought processes, they employ exercises that ask questions about your own production system, the same questions that they would ask you if they were standing in your facility as consultants. Your challenge is to think deeply about the answers, as well as the changes needed to make information flow both ways— • From the end customer through materials control to the production floor • On the production floor at the operator, team, and value stream level • And then from the production floor through the extended value stream Catalog no. PP7374, 2008, 168 pp., Soft Cover, ISBN: 978-1-56327-374-2, $47.95 / £29.99
Easier, Simpler, Faster Systems Strategy for Lean IT Jean Cunningham and Duane Jones "For too long IT systems have indirectly functioned as a barrier to Lean initiatives. ... This book breaks new ground because the authors fully illustrate just how IT can significantly hasten waste reduction." — Anand Sharma, President and CEO, TBM Consulting Group, Inc.
To enhance its Lean journey, a company must implement information systems that fully support the Lean initiative. In this book, Cunningham and Jones introduce a case study of an actual Lean implementation involving an IT system of a mid-size manufacturer, highlighting the IT issues faced during Lean transformation. The book suggests changes that will be required in an information system to make it a partner with, rather than a barrier to, a company becoming a Lean enterprise. It showcases opportunities that will arise for the information systems team to eliminate waste and apply Lean principles in its own operations. Catalog no. PP7353, 2007, 192 pp., ISBN: 978-1-56327-353-7, $35.95 / £22.99
Lean Software Strategies Proven Techniques for Managers and Developers Peter Middleton and James Sutton "Outstanding! A must read for software practitioners and technical leaders concerned with incorporating integrity and positive attributes into integrated systems design." — Barry Hendrix, Technical Fellow, Lockheed Martin
Winner of a Shingo Prize for Excellence in Manufacturing Research, this resource shows how the most advanced concepts of Lean production can be applied to the software development industry. Written for software engineers, developers, and project managers involved with creating Lean software processes and executing genuinely Lean projects, this book shows why many of the typical processes employed in software development are simply inadequate and can be enhanced by Lean. It draws on the personal experiences of the two authors as well as research on various software companies applying Lean production principles and tools in software development, especially for complex systems. Catalog no. PP7305, 2005, 468 pp., ISBN: 978-1-56327-305-6, $55.95 / £35.99
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INDUSTRIES / FUNCTIONS – IT Customer Satisfaction Planning Ensuring Product Quality and Safety Within Your MRP/ERP Systems Thomas T. Hirata This book presents a progressive, cost-cutting efficiency system that builds on material requirement planning (MRP) and enterprise resource planning (ERP) to facilitate improved customer satisfaction. It illustrates how shifting focus from inventory replenishment to customer service results in a better product, received exactly on time, at projected cost. The author elaborates on the classic "5 Whys" technique as it applies to customer satisfaction planning (CSP), explains manufacturing system evolution, looks at how to establish and personalize the customer relationship as well as rate and forecast clients, and presents examples of CSP in action. Furthermore, he explains why his novel system will change the face of modern business management, offers an implementation plan, and documents the adjustments in logic and strategy required to make major advances in inventory management and product assurance. Catalog no. PP3813, 2009, 120 pp., ISBN: 978-1-4200-8381-1, $41.95 / £26.99
Lean Performance ERP Project Management Implementing the Virtual Lean Enterprise, Second Edition Brian J. Carroll Series: Resource Management
Based on the author’s years of practical experience, this book presents a project management methodology that integrates strategy, people, process, IT, and Lean to manage the project implementation of a Virtual Lean Enterprise. Employing a conversational tone, it demonstrates the need to connect Lean performance with IT to achieve maximum Lean benefits, then discusses the best business process methodologies and ways to integrate them, including a Lean tool kit that requires participation from all departments of an organization • Provides project managers with an overview to present to Lean transformation committees • Presents a strategy for ERP project managers dealing with Chinese-based manufacturing • Discusses current events in the transition to Lean in the global economy • Includes new developments such as e-kanban and RFID • Features a case study of the Lean Commerce system implemented by Toyota North America Catalog no. AU0532, 2008, 456 pp., ISBN: 978-0-8493-0532-0, $77.95 / £49.99
A Tale of Two Systems Lean and Agile Software Development for Business Leaders Michael K. Levine "In the epilogue, Levine summarizes the lessons leaders should take away from this wonderful tale. This chapter alone is worth the price of the book; following the story brings a deep appreciation of its wisdom." — Mary Poppendieck, author of Implementing Lean Software Development: From Concept to Cash
This book considers two fictional systems development projects. One project proves to be an abject and expensive failure, while the other succeeds in creating a major new revenue stream and solving important customer needs. Contrasting the methods employed in a traditional, process-centric waterfall approach, with a Lean and agile-inspired approach, this book provides business leaders with a tangible understanding of why Lean thinking is so well-suited to contemporary environments requiring flexibility, speed, and the input of specialized knowledge. Catalog no. K10217, 2009, 344 pp., ISBN: 978-1-4398-0389-9, $49.95 / £31.99
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INDUSTRIES / FUNCTIONS – ACCOUNTING Practical Lean Accounting A Proven System for Measuring and Managing the Lean Enterprise Brian H. Maskell and Bruce Baggaley "… a highly readable and uncomplicated guide for financial and other managers of Lean companies … an invaluable reference for years to come." — Fred Garbinski, Parker Hannifin Corporation
With a value stream approach at its core, this book demonstrates how to transform a traditional accounting system to support a company's Lean initiative. The authors define the principles of Lean accounting and demonstrate ways to identify and eliminate wasteful transactions. They cover cell performance measurement, use of the box score, operational and financial planning, cost targeting, Lean accounting diagnostics, and value stream mapping. An included CD provides needed forms and charts. Designed as a hands-on manual for financial officers that will continue to serve as a resource following conversion, the book can also be used to win over a skeptical finance department. Look for a new edition of Practical Lean Accounting coming in the spring of 2011 – ISBN: 978-1-4398-1716-2 Catalog no. PP7243, 2004, 384 pp., Soft Cover, ISBN: 978-1-56327-243-1, $55.95 / £35.99
Target Cost Management The Ladder to Global Survival and Success Jim Rains “Target costing is one of the hidden treasures of companies like Toyota and Honda. … We are very fortunate that Jim Rains is bringing this precious information to us all. — Jeffrey K. Liker, author of The Toyota Way
“…a must read for every business executive interested in global success. … a respected world leader in value engineering provides the inspiration and details on how to incorporate target costing in your organization.” — Don J. Gerhardt, former Director, Value Engineering, Ingersoll-Rand; and President, Gerhardt Engineering
With a proven track record for helping companies achieve critical cost reductions without sacrificing customer satisfaction or raising prices, target costing provides a way to survive and prosper in today’s increasingly competitive market. This book details the preliminary steps required to institutionalize target costing and two necessary ingredients: proper organizational structure and cost tables. Catalog no. K11600, August 2010, 229 pp., ISBN: 978-1-4398-3559-3, $59.95 / £38.99
Making the Numbers Count Second Edition The Accountant as Change Agent on the World-Class Team Brian H. Maskell With his energetic tone and common sense approach, Maskell shows numbers people at all levels how that their responsibility during a Lean implementation is not to simply read the conventional bottom-line profit-and-loss results, but to measure and reflect on the processes influencing that bottom line. He provides the rationale, approaches, and tools that will lead to organizations that are flexible and responsive enough to function optimally in turbulent and unpredictable times. The book is updated throughout to reflect recent advances. Notably, it eliminates activity-based costing and management (ABC/M) in favor of the much more expedient value-stream accounting methods that have been tried and tested in diverse companies over the last ten years. Catalog no. PP0607, 2009, 243 pp., ISBN: 978-1-4200-9060-4, $39.95 / £24.99
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INDUSTRIES / FUNCTIONS – PRODUCT DEVELOPMENT Innovative Lean Development How to Create, Implement and Maintain a Learning Culture Using Fast Learning Cycles Timothy Schipper and Mark Swets “While innovation will always be messy business, the authors have eliminated much of the messiness. They have brought systematic thinking to something that does not lend itself to being systematic.“ — Bart Huthwaite, Sr., Huthwaite Innovation Institute
“This is truly a practitioner’s book. … If you follow the standards, you’ll be putting Lean development in place, and more important, you’ll be ensuring the behaviors and practices that sustain it. … there is little mystery involved; these are things you can teach, expect, observe, and audit.” — David Mann, author of Creating a Lean Culture
Incorporating Lean and the rules of structured innovation into the development process, this book unleashes the creativity of all involved in developing new products, services, or processes. Applying this approach, the authors have helped teams cut development time in half, while delivering award-winning quality solutions. They share those examples while providing a road map that all companies can follow to achieve a Lean development culture. Catalog no. PP2987, January 2010, 200 pp., Soft Cover, ISBN: 978-1-4200-9298-1, $39.95 / £25.99
The Toyota Product Development System Integrating People, Process, and Technology James Morgan and Jeffrey K. Liker "Absolutely brilliant …. This insightful book finally gives away the secrets of Toyota's Product Development System … read it, and there's no turning back." — Freddy Balle and Michael Balle, authors of The Gold Mine
"Product Development is one of the key frontiers of Lean thinking …. Learn how to turn the tables on the competition by reading this book." — Daniel T. Jones, co-author of The Machine that Changed the World
Morgan and Liker compare and contrast the world-class product development process of Toyota with that of a U.S. competitor. They use extensive examples from both competitors to demonstrate value stream mapping as a powerful tool for continuous improvement. Through real examples, they illustrate specific practices, such as multiple function workload leveling, compound process variation, effective technology integration, and knowledge management. Catalog no. PP7282, 2006, 400 pp., ISBN: 978-1-56327-282-0, $43.95 / £27.99
Value Stream Mapping for Lean Development A How-To Guide for Streamlining Time to Market Drew A. Locher Written by one of the world’s most respected consultants on Lean, this work presents a methodology for value stream mapping that is appropriate for any organization, whether it be service or product oriented. Over the past 25 years, Locher has proven just how powerful this process is, having employed it in healthcare, transportation, distribution, education, financial services, and manufacturing environments. Illustrating his methodology through the example of the imaginary DevelopTek company, he shows how managers can -• Identify development waste • Assess an organization’s current state and develop a Current State Map • Apply Lean principles to create a Future State Map • Develop a plan that will help realize that desired future Catalog no. PP7372, 2008, 144 pp., Soft Cover, ISBN: 978-1-56327-372-8, $47.95 / £29.99
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INDUSTRIES / FUNCTIONS – JOB SHOP & PROCESS MANUFACTURING Liquid Lean Developing Lean Culture in the Process Industries Raymond C. Floyd “If you truly want world-class performance, you will want a copy of this book on your desk as a ready reference manual.” — King Pouw, Executive Vice President, Kellogg Company
One of the first to successfully practice Lean in the chemical industry, Ray Floyd draws on his 20 plus years of experience to show how Lean manufacturing can be applied to the liquid industries. It includes invaluable information for those involved with reactive chemical manufacturing, petroleum and metal refining, and food and bio-pharma production. Catalog no. PP8629, February 2010, 346 pp., ISBN: 978-1-4200-8862-5, $49.95 / £31.99
Lean for the Process Industries Dealing with Complexity Peter L. King “… highly recommended.” —Janice M. Gullo, writing in APICS magazine
Drawing on 40 years of experience at one of the world’s largest chemical and materials manufacturers, King provides the first Lean resource written explicitly for the process industries. Focusing on where the needs of the process industry differ from those of parts assembly manufacturing, he discusses the eight wastes described in Lean literature, looking at how they manifest themselves in process operations. He explains how to adapt value stream mapping for process operations and how to identify and eliminate the root causes of bottlenecks. Catalog no. PP7851, 2009, 358 pp., ISBN: 978-1-4200-7851-0, $49.95 / £30.99
Made-to-Order Lean Excelling in a High-Mix, Low-Volume Environment Greg Lane "This book is an excellent resource … for those implementing a Lean manufacturing system in this environment." — Lee C. Banks, Senior VP and Operating Officer, Parker Hannifin Corp.
While Lean principles apply in high-mix, low-volume environments, implementation tools must be adapted and alternate methods embraced. Written by Greg Lane, one of the few individuals certified as a Toyota Production System Key Person, this book is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for shops that build to order. Catalog no. PP7362, 2008, 192 pp., Soft Cover, ISBN: 978-1-56327-362-9, $55.95 / £35.99
Creating Mixed Model Value Streams Practical Lean Techniques for Building to Demand Kevin J. Duggan "… must reading … shows you how to implement a Lean value stream in a way that everyone will understand." — Glynn Miller, Director, Consumer Centered Enterprise, Whirlpool,
Duggan goes beyond basic value stream mapping to show how to create future states in the real manufacturing world of multiple products, varying cycle times, and changing demand. An attached CD provides spreadsheets to help divide products into families and calculate resource needs. Catalog no. PP7280, 2003, 224 pp., Soft Cover, ISBN: 978-1-56327-280-6, $59.95 / £38.99
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INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENT Turbo Flow Using Plan for Every Part (PFEP) to Charge Your Supply Chain Tim Conrad and Robyn Rooks This book takes PFEP beyond the manufacturing cell to create a tool for managing the entire supply chain. Written by experts in supply chain integration, this text — • Discusses internal route planning and design using PFEP data • Details external logistics and synchronization of manufacturing, logistics, and inventory cycles • Explains how to manage raw material and WIP inventories using PFEP • Answers the question How much inventory do I need? Catalog no. K11093, November 2010, c. 96 pp., Soft Cover, ISBN: 978-1-4398-2067-4, $44.95 / £28.99
Lean Supplier Development Establishing Partnerships and True Costs Throughout the Supply Chain Chris Harris, Rick Harris, and Chuck Streeter Offering the same advice that they have successfully applied to corporations across the globe, the authors, award-winning consultants, provide the criteria needed to choose suppliers that will make good long-term partners, as well as a true cost model that eliminates guesswork when choosing what suppliers to develop. They supply proven PFEP methods to link your facility to the supply base and ways to develop and maintain information flow all along the supply chain. Real-world examples are used to illustrate solutions to likely contingencies. A quarterly supplier review is included that you can adapt for your own use. Catalog no. K10563, September 2010, 218 pp., Soft Cover, ISBN: 978-1-4398-1125-2, $49.95 / £31.99
Implementing Lean Six Sigma throughout the Supply Chain The Comprehensive and Transparent Case Study Elizabeth A. Cudney and Rodney Kestle From start to finish, this book details a case study that follows the implementation of a Lean Six Sigma improvement project across a supply chain. Unlike most published case studies, which give only an overview, this in-depth case presents the data, and explains in detail how the team drew its conclusions. In addition, the authors provide a comprehensive glossary of Lean and Six Sigma terminology. The book covers use of value stream maps, focus groups, dashboards and scorecards, as well as other methods to identify stakeholder needs, the Voice of the Customer, and areas of waste. Each chapter concludes with exercises. An accompanying CD contains all data used throughout the study, so that readers can duplicate the analyses. Catalog no. K11389, October 2010, c. 288 pp., Soft Cover, ISBN: 978-1-4398-2814-4, $59.95 / £38.99
Lean Culture for the Construction Industry Building Responsible and Committed Project Teams Gary Santorella Written by a veteran in the construction field, this reference is the first to address the direct application of Lean initiatives to that industry. It uniquely addresses people issues in terms of productivity and waste by applying behavioral psychology principles at a tactical level. The author expands the notion of ethics beyond the simple litmus test of right and wrong, so team leaders can adopt proper professional and diplomatic attitudes and behaviors toward the implementation of Lean improvements. An emphasis is placed on flexibility and allowing for contingencies. The author recounts real-world stories to which every construction professionals can relate. Catalog no. K11583, December 2010, c. 264 pp., ISBN: 978-1-4398-3508-1, $59.95 / £38.99
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INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENT Mastering Purchasing Management for Inbound Supply Chains Thomas A. Cook Many of the lessons about inbound supply – especially foreign purchasing – are far less costly when learned through others’ experience rather than your own. Leaving little to chance, international trade expert, Thomas Cook details all the basic fundamentals of logistics and compliance, while also offering essential insight that even seasoned supply managers will find valuable. He covers the importance of bonded warehouses and cost modeling. He presents case studies from a variety of industries that illustrate best practices while revealing those things that the savvy trader should know about foreign trade zones. Catalog no. PP6197, October 2010, c. 420 pp., ISBN: 978-1-4200-8619-5, $79.95 / £49.99
Fix Your Supply Chain How to Create a Sustainable Lean Improvement Roadmap Paul Husby and Dan Swartwood “If you value continuous improvement and are looking to gain a better understanding of complementary methodologies, this is your book.” — Jerome Hamilton, 3M Director, Lean Six Sigma and Initiatives
Written by business leaders for business leaders, this book explores successful supply chain improvement requirements and methodologies. It covers the use of these techniques in a story about Twin City Manufacturing, a fictitious company based on the authors’ 70 years of combined experience. Whether you are intimately familiar with SCM or have limited experience, the authors present a valuable roadmap that you will be able to immediately apply to supply chain improvement. Catalog no. PP7381, 2009, 214 pp., ISBN: 978-1-56327-381-0, $49.95 / £30.99
Kanban for the Supply Chain Fundamental Practices for Manufacturing Management Stephen Cimorelli Cummins Filtration, Nashville, Tennessee, USA
Written for supply chain managers seeking to improve material flow, this work explains how to make the conversion from materials requirements planning push techniques to the pull techniques intrinsic to kanban replenishment systems. It shows how to install fundamental kanban concepts that quickly lead to increased productivity and profitability. Through an iterative process of planning, adjusting, and executing, dynamic kanban pull techniques keep inventory levels synchronized with demand, and keep the supply chain running apace with actual production. Includes training materials for instructors: communication notes, exercises, and figures Catalog no. PP7314, 2006, 244 pp., Soft Cover, ISBN: 978-1-56327-314-8, $49.95 / £31.99
Compliance in Today's Global Supply Chain Thomas A. Cook Managing director of American River International and a Department of Commerce appointee to the New York District Export Council, Thomas Cook is one of the most accomplished experts on international trade. In this comprehensive yet accessible resource, he provides a step-by-step blueprint for executing a corporate global trade program that is both compliant and cost-effective. The text identifies both traditional concerns and emerging complications, and then puts forward strategies to address them. In providing cost-effective solutions for building and securing a global supply chain, Cook emphasizes continuing education that will sensitize all levels of an enterprise to the importance of abiding by changing regulations. Catalog no. AU6219, October 2010, c. 291 pp., ISBN: 978-1-4200-8621-8, $79.95 / £49.99
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INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENT The Supply Chain in Manufacturing, Distribution, and Transportation Modeling, Optimization, and Applications Edited by
Kenneth D. Lawrence, Ronald K. Klimberg, and Virginia M. Miori Focusing on research that integrates production, distribution, and transportation, this book provides solutions to significant problems within the supply chain integration process. The text presents both tactical and operational models that address a wide variety of organizational issues, including high-level production schedules, product sourcing, network alignment, distribution center layouts, transportation operations with consistent demand, inventory planning, as well as dayto-day operations planning. Leading contributors from industry and academia also provide real-world business applications and case studies that feature some of the modeling solutions discussed in the chapters. Catalog no. AU945X, September 2010, 320 pp., ISBN: 978-1-4200-7945-6, $89.95 / £57.99
Closed-Loop Supply Chains New Developments to Improve the Sustainability of Business Practices Edited by
Mark E. Ferguson and Gilvan C. Souza Series: Supply Chain Integration Modeling, Optimization and Application
“From the strategic decisions made at the executive suite down to the tactical decisions of the production floor, this book offers much insight for any manager interested in adopting a more sustainable business model.” — John R. Wells, President and CEO, Interface Americas
Written in language that is accessible to practitioners, this authoritative resource examines recent research and case studies of companies running profitable reuse/remanufacture operations in various industries. It illustrates profitable practices in returned and recovered products, clearly explaining how to: design a reverse logistics network, conduct production planning, implement effective marketing strategies, and apply closed-loop supply chain strategies in industries besides manufacturing. From product development to materials to assembly and profitability, this complete resource explores the impact of these processes across all aspects of the supply chain. Catalog no. AU9525, April 2010, 257 pp., ISBN: 978-1-4200-9525-8, $79.95 / £49.99
Introduction to Supply Chain Management Technologies Second Edition David Frederick Ross Series: Resource Management
Updated to include the latest advances of Web 2 technologies and their increasingly ubiquitous nature, the new edition of this invaluable resource continues to explore the concepts, techniques, and vocabulary at the convergence of supply chain management and the Internet. Written by a recognized expert with more than three decades of SCM experience, it highlights the integrative software toolsets and suites that will allow supply chain partners to move to new levels of collaboration, flexibility, and overall performance. It covers ways to optimize demand management, manufacturing, and distribution functions. Perhaps most importantly, this book and the technology it champions can help empower executives involved with restarting a stalled economic environment. Catalog no. K11705, November 2010, c. 422 pp., ISBN: 978-1-4398-3752-8, $79.95 / £49.99
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INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENT Supply Chain Management at Warp Speed Integrating the System from End to End Eli Schragenheim, H William Dettmer, and J. Wayne Patterson "A must-read business book, not only for supply chain managers, but also for every decision maker in the company." — Santiago Cuadra, Director, Information Management, AkzoNobel Paints, Pte. Ltd.
"This book advances Theory of Constraints knowledge for production and distribution to a new level. Everyone concerned with supply chain improvement and applying TOC to these fields should read it." — Paul Bayer, Quality Manager, BMW Munich
This sequel to the bestselling Manufacturing at Warp Speed refines and updates the former approach to production management with new ideas that complement earlier tactics. This is the first book to describe, in detail, the application of the Theory of Constraints approach to assured availability in distribution, for both original equipment manufacturers and retailers. The authors address the new demands taken on when a firm accepts rush orders. They also review the issues surrounding availability and the management of inventory moving through distribution systems. Catalog no. AU7335, 2009, 232 pp., ISBN: 978-1-4200-7335-5, $79.95 / £48.99
Improving the Extended Value Stream Lean for the Entire Supply Chain Darren Dolcemascolo Organized in a workbook format, this volume presents a systematic approach for extending Lean manufacturing across the entire supply chain. The author presents proven methods for sustaining success and continuously improving the entire supply chain, which should result in increased profits, reduced lead times, lower inventory, and better quality. The book includes tips on how to magnify the benefits of Lean on the production floor by extending the Lean principle throughout the enterprise. Techniques addressed in the book include extended value stream mapping, process kaizen, supplier evaluation, and supplier integration, as they relate to Lean supply chains. Provides invaluable information for companies deciding what should and should not be outsourced Catalog no. PP7333, 2006, 224 pp., Soft Cover, ISBN: 978-1-56327-333-9, $49.95 / £31.99
Lean Supply Chain Management A Handbook for Strategic Procurement Jeffrey P. Wincel "Lean supply chain management is a core competency … and if you are serious about developing this competency I recommend that you read this book." — Jeffrey K. Liker, author of The Toyota Way
Unlike other strategic procurement guides, this handbook considers an organization's business condition as a contributing factor in the development of a strategic procurement strategy. That is, rather than taking a one-size fits all approach, the author takes a more individualized approach, illustrating techniques specific to organizations operating in a standard or crisis environment. With methods for developing and tracking strategic procurement initiatives, this book provides purchasers and supplier development professionals with the tools needed to transform procurement from a mere cost center to a profit generator. Catalog no. PP7289, 2004, 256 pp., ISBN: 978-1-56327-289-9, $49.95 / £31.99
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METHODS & TOOLS – VALUE STREAM MANAGEMENT Mapping the Total Value Stream A Comprehensive Guide for Production and Transactional Processes Mark A. Nash and Sheila R. Poling While other books focus on production process value stream mapping or transactional process mapping, this work meets the needs of manufacturers and service sector organizations by detailing both. It teaches readers what techniques are commonly applicable to any type of organization, and also explains areas of difference, so that map makers will be able to adapt to whatever situations arise. Extending the lessons originally put forward in Value Stream Management for the Lean Office, this highly practical resource — • Reinforces fundamental concepts and theoretical models with real-world applications and complete examples of VSM • Advances the calculation of process lead time for work queues to cover the very real possibility of having more work in the queue than available time • Extends the concept of availability to cover employees as well as equipment Catalog no. PP7359, 2008, 296 pp., Soft Cover, ISBN: 978-1-56327-359-9, $47.95 / £29.99
Value Stream Management Eight Steps to Planning, Mapping, and Sustaining Lean Improvements Don Tapping, Tom Luyster, and Tom Shuker "… exceptional for use in training. … also excellent for busy managers/executives who are typically overloaded with material. … You can tell this book is written by practitioners who have actually done it." — Bob Angeli, Vice President of Operations, IdraPrince
Value stream management simplifies planning for Lean implementation. It links the metrics and reporting required by management with the tools needed on the manufacturing floor. In this volume, the authors stress the importance of reaching beyond single-point kaizens to ensure a sustainable Lean implementation process. The central feature of this work is the value stream management storyboard, a tool representing an eight-step process for Lean implementation. The storyboard brings together people, tools, metrics, and reporting into one visual document. The book is packaged with a CD containing a Lean assessment tool and a storyboard template, as well as charts, forms, and worksheets. Catalog no. PP7245, 2002, 176 pp., Soft Cover, ISBN: 978-1-56327-245-5, $49.95 / £31.99
Value Stream Management DVD Set Eight Steps to Planning, Mapping and Sustaining Lean Improvements This learning package starts with an overview of value stream management and the basics of lean. Subsequent lessons will teach you how to map your current state; how to plan and map your future state in three stages — demand, flow, and leveling; how to create action plans; and how to develop a storyboard that communicates the entire process. You will see value stream management in action at Wiremold, Mercedes Benz, Pella Windows, and Thetford. Finally, a computer-generated virtual factory will show how the system comes together and how lean actually works. In addition to the two hour DVD, the package includes a facilitator guide and participant guide and a CD with blank forms and blank map. Visit the product description at our website for a free demonstration. Catalog no. PP7338, 2006, DVD (approx 120 min), ISBN: 978-1-56327-338-4, $2099.00 / £1337.00
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METHODS & TOOLS – PROBLEM SOLVING The A3 Workbook Unlock Your Problem-Solving Mind Daniel D. Matthews Facilitating participation and responsibility across an entire organization, this oneof-a-kind workbook takes readers step-by-step through the disciplined development of an A3 report, a single-sided piece of paper used by Lean industries to promote efficiency. The A3 provides all employees at all levels with a method to quickly identify a problem, analyze its root cause, select appropriate countermeasures, and communicate necessary actions to decision makers. The workbook includes worksheet templates that can be reproduced and used in future problem solving efforts. Just as important as the end result, The A3 encourages an attitude of efficiency and a willingness to drill down to the true cause of any sort of waste or inefficiency. Catalog no. K11572, October 2010, c. 184 pp., Soft Cover, ISBN: 978-1-4398-3489-3, $49.95 / £31.99
Basics of Process Mapping 2nd Edition Robert Damelio Since the influential first edition of this bestselling text, many organizations have become familiar with systematic improvement approaches such as Six Sigma, Lean, CMMI®, and the Balanced Scorecard, The first step with any of these is to detail processes and identify areas of inefficiency. Updated with new chapters and new tools, this volume demonstrates how process mapping can be used to initiate any improvement strategy. It shows how to employ the three levels framework, which allows you to evaluate situations and draw maps for the same work at the organization, process, and job/performer levels. While most texts on mapping focus on manufacturing, this book concentrates on service and knowledge work. • Provides new tools to make work processes more clearly visible • Compares and contrasts process maps with value stream maps • Includes sample maps and examples that relate to the service and knowledge industries Catalog no. PP7376, November 2010, c. 192 pp., Soft Cover, ISBN: 978-1-56327-376-6, $15.00 / £9.99
The Basics of FMEA 2nd Edition Raymond J. Mikulak, Robin McDermott, and Michael Beauregard Fully updated with enhanced methods to reflect the latest ISO 9000 and ISO/TS 16949 standards, this second edition systematically assists developers and engineers in achieving quality and cost efficiency. Written by consultants at a highly respected engineering firm, this manual fully defines Failure Mode and Effect Analysis and provides a definitive ten step method for its implementation illustrated by an extended case study. The book demonstrates how to involve all stakeholders in the process so as to identify and preemptively eliminate those product deficiencies that originate in production. With a long track record of success in the military and the automotive industry, FMEA is now being applied to production concerns across a variety of industries. Includes ready-to-use worksheet templates Catalog no. PP7377, 2009, 90 pp., Soft Cover, ISBN: 978-1-56327-377-3, $15.95 / £10.99
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METHODS & TOOLS – 5S Visual Controls Applying Visual Management to the Factory Chris A. Ortiz and Murry Park Leaving little room for mistake, this book lays out what might be the most detailed approach to applying the Lean principles of 5S needed to convert a factory to a fully functional Visual Workplace. The book offers a clear discussion on management's role in creating a Lean strategy that will implement the visual factory, while also molding the workplace culture needed to sustain it. A crucial section of the book is dedicated to discussing how to design and create visual shadow boards, that part of the process where many efforts stumble. It also discusses right-sizing, kanban, and ways to measure performance. Catalog no. K11109, December 2010, c. 152 pp., Soft Cover, ISBN: 978-1-4398-2090-2, $39.95 / £25.99
5S for Operators 5 Pillars of the Visual Workplace Hiroyuki Hirano Shopfloor Series
"I recommend this book to every supervisor who wants a commonsense, inexpensive method for improving quality, productivity, and morale within their department." — Jaymie Randel, Training Coordinator, Douglas and Lomason Company
Since its publication, Hiroyuki Hirano’s, 5S for Operators continues to prove its value in one company after another. Hirano’s five pillars of the visual workplace: Sort, Set in Order, Shine, Standardize and Sustain are the most fundamental and often overlooked aspects in continuous improvement initiatives. Easy-to-read and apply, the book provides guidance for supervisors but can also be used as textbook for on the floor study groups. Each section of the book is loaded with questions, outlines, summaries, diagrams and illustrations. This book provides the foundation that is essential for implementing not just 5S, but overall manufacturing improvements like shorter equipment changeovers, just-in-time inventory, and total quality management and total productive. Catalog no. PP7123, 1996, 136 pp., Soft Cover, ISBN: 978-1-56327-123-6, $28.95 / £17.99 See page 8 for other books in the Shopfloor Series
5 Pillars of the Visual Workplace Hiroyuki Hirano "… both a groundbreaking book on continuous improvement and a handy guide to the details of creating a superior workplace. Diligently applied, the 5S's will decrease expenses and boost productivity." — Jeff Olson, Editor, Soundview Executive Book Summaries
In this pioneering work, Hirano introduces his 5s system, explains why it so important, and offers guidelines for it nuts and bolts implementation. Filled with numerous case studies, graphic illustrations, 40 plus user forms, and training materials, it is a must-have reference for organizations seeking to thrive into a highly competitive climate. Addressing the incredulous reaction of executives who deride the process for its simplicity, the author warns of disastrous consequences for companies that fail to recognize its value; if they cannot successfully implement 5S, there is little hope of integrating large-scale changes such as JIT or re-engineering. Catalog no. PP7047, 1995, 384 pp., ISBN: 978-1-56327-047-5, $98.95 / £62.99
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METHODS & TOOLS – 5S The 5S Pocket Guide James Peterson and Roland Smith Written for workers on the floor, this guide is designed to enhance awareness of the principles behind the 5S System and identify its impact on improving efficiency and promoting a safe working environment. Using a condensed format, it outlines a disciplined methodology for implementing 5S, organized around a six-step method. The innumerable benefits of the 5S System include shorter cycle times, increased floor space, reduced lead times and training cycles, lowered accident rates, enhanced communication, and less inventory. By employing this handy resource, organizations can more easily build employee awareness of 5S throughout their plants, leading to dramatic improvements in productivity, safety, and profitability. Catalog no. PP6338, 1998, 64 pp., Soft Cover, ISBN: 978-0-527-76338-1, $8.95 / £5.99
5S System Kit Workplace Organization and Standardization Press Productivity and Tel-A-Train Complete with facilitator and participant guides, the 5S System DVD is used to train new employees, launch kaizen events, and lead implementation activities within your workforce. It will teach your employees how to seize control of their workplace, how to own their equipment, and most importantly, how to foster an environment of continuous improvement on the shop floor. Covering actual 5S implementation in plants such as Ford, Titleist and Foot-Joy Worldwide, Miller Brewing, Exxon Chemicals, Gelman Sciences, and Delco Remy, managers and improvement specialists will see how 5S has worked for others and how it can work for them. The kit includes a DVD (approx 90 min), Facilitator Guide, and Participant Guide. Visit the product description at our website for a free demonstration. Catalog no. PP5837, 1998, DVD (approx. 90 min), ISBN: 978-1-4200-7583-0, $2099.00 / £1167.00
5S for Operators Learning Package Hiroyuki Hirano Thorough, flexible, and almost infinitely customizable, the 5S for Operators Learning Package allows instructors to conduct learning sessions tailored to any organization. That customizability combined with modules specifically designed to encourage workers to become actively involved in the learning process makes for a high-impact learning experience the workforce won't soon forget. The 5S for Operators Learning Package contains: Leader's Guide, 5 copies of 5S for Operators, a CD with additional presentation materials, and a copy of the classic 5 Pillars of the Visual Workplace. Based on that classic, this package provides support in continuous improvement efforts. Catalog no. PP7124, 1996, Pack, ISBN: 978-1-56327-124-3, $390.00 / £250.00
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METHODS & TOOLS – MISTAKE-PROOFING Standardized Work for Noncyclical Processes Joseph Niederstadt Many companies fail to apply rigor to the standardization of noncyclical work, believing that it cannot be measured. This book cuts to the core of that mistaken belief by showing you how to measure non-repeating job processes and eliminate waste associated with noncyclical activities and indirect labor assignments through their standardization. Taking a deliberate hands-on approach reflective of his own time as an operator on the line, Niederstadt lays out the methods that he has instituted in more than 30 factories globally. He covers activities involving multiple machine job setters, maintenance, stockers, and quality auditors. Includes a CD with templates of all the forms used, and color versions of images found in the text Catalog no. K11219, August 2010, 120 pp., Soft Cover, ISBN: 978-1-4398-2550-1, $39.95 / £25.99
New Horizons in Standardized Work Techniques for Manufacturing and Business Process Improvement Timothy D. Martin and Jeffrey T. Bell Understanding the thinking behind standardized work is essential to realizing its maximum benefits. This book is an all-inclusive guide to applying standardized work principles to virtually any situation or process. It includes an array of examples that demonstrate how the concepts can be applied in a variety of industries and business applications. In a step-by-step format, the book discusses the relationship of the work period of takt time – as expressed in the short-cycle , long-cycle, and non-cyclic applications – parallel work steps, takt boards, the three main worker interface levels in job designs, and their applications. Catalog no. K11891, January 2011, c. 176 pp., Soft Cover, ISBN: 978-1-4398-4080-1, $49.95 / £31.99
Strategic Error-Proofing Achieving Success Every Time with Smarter FMEAs John J. Casey Developed by manufacturing visionary John Casey, SET defines a logic stream for engineers to strategically incorporate no-cost or low-cost error-proofing devices to help production operators. The operators interface with their parts and tools in such a way that either the product is made correctly, or the process is stopped. Operators can make only good parts—nothing else. Succinctly addressing the shop floor realities and cultural challenges that can conspire to defeat even the best intentions, this volume — • Shows how to integrate error-proofing devices into both planning and production • Outlines a method to measure the robustness of each operation as well as overall plant efficiency • Helps you develop a library of standardized methods for solving your most common problems Catalog no. PP8367, 2009, 152 pp., Soft Cover, ISBN: 978-1-4200-8367-5, $36.95 / £23.99
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METHODS & TOOLS – MISTAKE-PROOFING Poka-Yoke Improving Product Quality by Preventing Defects Nikkan Kogyo Shimbun If your goal is zero defects, poka-yoke (mistake-proofing) as a worker tool will help you get there. Greater participation by workers can only improve your processes, your products, and your company as a whole. The first section of this book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section offers 240 examples of poka-yoke improvements implemented in Japanese plants, which can be used as catalysts in study groups. Improvement forms are included that can help capture ideas. Catalog no. PP9931, 1989, 304 pp., ISBN: 978-0-915299-31-7, $82.95 / £52.99
Zero Quality Control Source Inspection and the Poka-Yoke System Shigeo Shingo A combination of source inspection and mistake-proofing devices is the only method to get you to zero defects. Shigeo Shingo shows you how this proven system for reducing errors turns out the highest quality products in the shortest period of time. Shingo provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement. He also discusses inspection systems, quality control circles, and the function of management with regard to inspection. This classic volume provides a wealth of insight that is just as valuable today as when it was first published 25 years ago. Catalog no. PP9907, 1986, 336 pp., ISBN: 978-0-915299-07-2, $87.95 / £56.69
Make No Mistake! An Outcome-Based Approach to Mistake-Proofing C. Martin Hinckley The centerpiece of Hinckley’s unique mistake-proofing approach is an outcomebased classification system that focuses on preventing rather than detecting defects. To this end, he offers an amazing encyclopedic compilation of mistakeproofing tools. Based on the irrefutable premise that mistake-proofing is a skill that improves through familiarity with previous solutions, Hinckley’s classification systems is designed to help you find outstanding rather than random solutions to current problems on the shop floor. The book includes mistake-proofing documentation forms that will help you adapt his methodology to your own defect prevention efforts. Catalog no. PP7227, 2002, 440 pp., ISBN: 978-1-56327-227-1, $87.95 / £56.69
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METHODS & TOOLS – QUICK CHANGEOVER A Revolution in Manufacturing The SMED System Andrew P. Dillon and Shigeo Shingo "One of the most thought provoking manufacturing books anyone can read." — Ken Stork, Past President, AME Target
“Because of Dr. Shingo's direction, we have been able to reduce changeover time from 4 to 5 hours to an average of 2.5 to 4 minutes." — Gifford M. Brown, Plant Manager, Cleveland Engine Plants, Ford Motor Company
From the industrial engineer who developed SMED (single-minute exchange of die) for Toyota, this volume provides a full overview of this powerful just in time production tool. It offers the most complete and detailed instructions available anywhere for transforming a manufacturing environment in ways that will speed up production and make small lot inventories feasible. The text delves into both the theory and practice of the SMED system, explaining fundamentals as well as techniques for applying SMED. The critically acclaimed text is supported with hundreds of illustrations and photographs, as well as 12 chapter-length case studies. Catalog no. PP9903, 1985, 383 pp., ISBN: 978-0-915299-03-4, $87.95 / £56.69
Kaizen for Quick Changeover Going Beyond SMED Keisuke Arai and Kenichi Sekine "Close to the ground, real-life examples of continuous improvement techniques that relate to virtually any type of production environment." — John Gugliotta, V.P. Operations, Lifeline Systems, Inc.
Picking up where Shingo's Single Minute Exchange of Die left off, this book streamlines the process even further to reduce changeover time, while simultaneously cutting staffing requirements in half. The book begins by outlining the tactical principles for improving the three phases of the changeover procedure. Next, it demonstrates how to improve changeover on a processing line. All of the ideas presented are based on kaizen improvements, which require very little, if any, expenditure. Process razing and the implementation of one-piece flow are also examined as means to eliminate wasteful transportation and searching. Catalog no. PP7341, 2006, 320 pp., Soft Cover, ISBN: 978-1-56327-341-4, $59.95 / £38.99
Winners Circle DVD Press Productivity Featuring Indianapolis 500 winners Danny Sullivan and Rick Mears, this highly motivational video introduces the quick changeover technique invented in Japan. The video compares the way a racing pit crew functions to a die changeover team in a manufacturing environment. It shows how both must function as a cohesive unit to succeed. It also takes you inside a company that reduced die-changeover from over two hours to less than five minutes. The video is an excellent way for you to introduce quick changeover techniques to your employees. It is fast paced and explains the basic concepts of teamwork in a die-exchange.
Catalog no. PP7633, 2003, DVD (approx 20 min.), ISBN: 978-1-4200-7633-2, $209.95 / £133.00
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METHODS & TOOLS – QUICK CHANGEOVER Quick Changeover Simplified The Manager's Guide to Improving Profits with SMED Fletcher Birmingham and James Jelinek "The SMED program has helped us realize greater manufacturing flexibility in the molding area and all the associated benefits: lower inventory, shorter lead times and responsiveness to our internal and external customers." — Linas Biliunas, Director, Manufacturing Operations, Kinetico Inc.
Concise and readily accessible, this critically acclaimed guide is written for companies that need to implement a quick setup and changeover program, but aren't sure where to start. The authors walk busy readers through basic concepts and the process of implementing a mini setup reduction program. They provide quick changeover tools selected for their ease of implementation. All the examples, including ROI statistics, come from real companies that have successfully implemented the strategies and tools discussed. This program offers a good starting point for those companies wanting to ultimately install a full-scale program. Catalog no. PP7349, 2007, 128 pp., Soft Cover, ISBN: 978-1-56327-349-0, $32.95 / £20.99
Quick Changeover for Operators The SMED System Shigeo Shingo Shopfloor Series
SMED (Single-Minute Exchange of Die) is a method that facilitates equipment or product changeovers in record time--often less than 10 minutes. Developed from, A Revolution in Manufacturing: The SMED System and written for managers, this book is intended for frontline production and assembly associates. It explains why SMED is important and examines the basic stages of SMED. The authors organized the material into chunks of information that can be covered in a series of short sessions. Each chapter includes reflection questions to stimulate group discussion. Catalog no. PP7125, 1996, 96 pp., Soft Cover, ISBN: 978-1-56327-125-0, $28.95 / £17.99 See page 8 for other books in the Shopfloor Series
Quick Changeover for Operators Learning Package Press Productivity This package provides the foundation for launching a fullscale implementation process that gets all of your workers involved. It provides immediate practical skills offered in a flexible curriculum that adapts to your requirements. Each learning package includes: • A Leader’s Guide • 5 copies of Quick Changeover for Operators: The SMED System • A CD filled with additional presentation materials • A copy of A Revolution in Manufacturing: The SMED System, by Shigeo Shingo (page 54) Catalog no. PP7126, 1996, 174 pp., Pack, ISBN: 978-1-56327-126-7, $390.00 / £250.00
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METHODS & TOOLS – CELLULAR MANUFACTURING Self-Balancing Processes True Lean Continuous Flow Gordon Ghirann Self-balancing is a simple, elegant solution to line-balancing and a breakthrough in achieving flow. Since the first assembly lines of Henry Ford, solutions to line balancing have been cumbersome and have never achieved real balance or flow. This book provides detailed descriptions of the methods, debugging tools, simulation software, and layouts for achieving true continuous flow in both simple and complex environments. The text offers solutions to the problems associated with standard line balancing, such as inventory buffers, variation, and operator pace and offers a shortcut for achieving true continuous flow. Various case studies illustrate the real power that this method has on manufacturing. Catalog no. K11034, February 2011, c. 200 pp., Soft Cover, ISBN: 978-1-4398-1965-4, $44.95 / £27.99
Reorganizing the Factory Competing Through Cellular Manufacturing Nancy Hyer amd Urban Wemmerlov "… a great handbook for a manager either just starting to investigate cells or someone experienced with cells and looking to upgrade ... . It also addresses … setting up office cells. Many companies don't realize the large potential benefits of going cellular in the office as well as on the manufacturing floor.” — Ronald Leong, Manager, Delphi Automotive Systems
This Shingo Prize recipient presents a thoroughly researched and comprehensive life-cycle approach to cellular work organizations. It takes you from the basic cell concept and its benefits through the process of justifying, designing, implementing, operating, and improving this new type of work organization in offices and on the factory floor. The book discusses many important technical dimensions, such as factory analysis, cell design, planning and control systems, and principles for lead time and inventory reduction. It also covers managerial issues that arise when organizing work into cells. Catalog no. PP7228, 2002, 874 pp., ISBN: 978-1-56327-228-8, $109.95 / £69.99
Cellular Manufacturing One-Piece Flow for Workteams Productivity Development Team Shopfloor Series
Straightforward and free of frill, this workbook introduces production teams to basic cellular manufacturing and teamwork concepts and orients them for participating in the design of a new production cell. Use this book to get everyone on board to reduce lead time, work-in-process inventory, and other profit-draining wastes. Each chapter includes an overview and a summary to reinforce concepts, as well as reflection questions, which can be used to encourage group discussions. This volume is part of the Productivity Press Shopfloor Series, which offers a simple, cost-effective approaches for building basic knowledge about key manufacturing improvement topics Catalog no. PP7213, 1999, 88 pp., Soft Cover, ISBN: 978-1-56327-213-4, $28.95 / £17.99
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METHODS & TOOLS – KANBAN Custom Kanban Designing the System to Meet the Needs of Your Environment Raymond S. Louis "This is the first kanban book I have read which clearly understands that there is a significant difference between environments. … highly innovative, insightful, and clearly written by an author who has years of implementation experience." — Terry O'Neill, Vice President, Operations, CMS Products
"Exceptionally comprehensive and detailed … provides detailed action plans for implementation in multiple environments." — Henry M. Lee, Manager, Operations, Gulf States Toyota
Raymond Louis demonstrates how to develop and implement a successful kanban system by selecting appropriate techniques based on the environmental factors and needs of specific organizations. The book fully explains each technique, including a description of the environment and type of company it is intended to serve. In all, the author explains more than 20 design options and associated replenishment techniques, so that most every reader will be able to custom develop his or her own kanban system. This is the only text that thoroughly deals with both the design and implementation of a complete kanban system. Catalog no. PP7345, 2007, 256 pp., ISBN: 978-1-56327-345-2, $49.95 / £31.99
Kanban Just-in Time at Toyota Management Begins at the Workplace Japan Management Association Toyota’s world-renowned success proves that Just-in-Time (JIT) makes other manufacturing practices obsolete. This simple but powerful book is based on the seminars given by Taiichi Ohno and other senior production staff to introduce Toyota’s own supplier companies to JIT. It teaches the philosophy and implementation of what many call the most efficient production system in the world. Real and typical results at American companies after reading this book: • Lead-time on one product was reduced from 12 weeks to 4 days • Setup time on a large blanking press was reduced from eight hours to one minute and four seconds • Work-in-process reduced 50 percent plant-wide • Factory floor space opened up 30 to 40 percent Catalog no. PP9948, 1986, 224 pp., ISBN: 978-0-915299-48-5, $55.95 / £35.99
Kanban for the Shopfloor Learning Package Productivity Press Development Team A complete and flexible curriculum for teaching kanban and making it part of your company’s culture and mode of operation, the learning package shows the difference between kanban and conventional ordering systems. The kanban learning package includes the following: • Leader’s Guide • 5 copies of Kanban for the Shopfloor • 1 laminated job aid: A Kanban Implementation Summary • 1 copy of the classic book Kanban: Just-in-Time At Toyota • Additional presentation materials on CD Catalog no. PP7284, 2004, Pack, ISBN: 978-1-56327-284-4, $390.00 / £250.00
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METHODS & TOOLS – SIX SIGMA / STATISTICS Corporate Sigma Optimizing the Health of Your Company with Systems Thinking Anwar El-Homsi and Jeff L. Slutsky “… the clearest, simplest and most practical book I have ever read on this subject.” — Stephen G. Haines, founder and CEO of Haines Centre for Strategic Management
Proposing that corporations, like human bodies, have vital systems that must be cared for, this book outlines how to monitor these vital organs in a corporation. It provides a roadmap for leaders to plot a course from where they are now, to where they want to be. It begins by describing how leaders formulate effective organizational vision, mission and values, how to foster and nurture shared organizational vision to succeed, and how to clearly define strategic balanced business objectives. The book identifies the function of organizational departments and shows how to assess the quality level or health of these departments using both Lean and Six Sigma improvement tools. Catalog no. K10219, January 2010, c. 288 pp., ISBN: 978-1-4398-0394-3, $44.95 / £28.99
DOE Simplified Practical Tools for Effective Experimentation, Second Edition Mark J. Anderson and Patrick J. Whitcomb "By taking situations from everyday life and using simple language to transfer them to manufacturing and laboratory environments, the authors have made an often dry, difficult subject attainable for the uninitiated." — Jay Yongless, Assistant Editor, Quality in Manufacturing
Offering a planned approach for determining cause and effect, this work provides researchers with the statistical means to analyze how numerous variables interact. With this second edition, Anderson and Whitcomb retain their lively approach to the learning of fundamentals, lightening up the text with interesting sidebars and amusing anecdotes. They offer a four-step planning process for designing and executing experiments. Accompanying the book is a 180-day trial for Stat-Ease's newest software: Design-Ease®,v. 7, which assists with mathematic computations, allowing one to focus on data analysis. Catalog no. PP7344, 2008, 256 pp., Soft Cover, ISBN: 978-1-56327-344-5, $49.95 / £31.99
RSM Simplified Optimizing Processes Using Response Surface Methods for Design of Experiments Patrick J. Whitcomb and Mark J. Anderson "… a thorough but succinct overview of response surface methods. It equips typical engineers or industrial scientists with all that they will need to start using these powerful optimization techniques… ." — John D. Guerin, President, Turning Points Management Consulting, Inc.
A complete demystification of response surface methods (RSM), this book takes a simple-and-fun approach that provides knowledge on RSM in an easy informal style. Keeping formulas to a minimum and making liberal use of figures, charts, graphs, and checklists, the book offers relevant examples, amusing sidebars, and do-it-yourself exercises that lead readers to the peak potential for their product quality and process efficiency. The book includes a 180-day trial for Stat-Ease's newest software: Design-Ease®,v. 7, which allows readers to do complex statistical computations, generate graphics, and perform numerical optimization. Catalog no. PP7297, 2005, 304 pp., Soft Cover, ISBN: 978-1-56327-297-4, $59.95 / £38.99
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METHODS & TOOLS – SIX SIGMA / STATISTICS Using Lean for Faster Six Sigma Results A Synchronized Approach Mark Nash, Sheila R. Poling, and Sophronia Ward "Those who are interested in getting past all the theory and want to get on to making money must read this no-nonsense book." — Skip Steward, Plant Operations Manager, Emerson
"An absolute 'must read' for those embarking on the Lean Six Sigma journey and an excellent resource guide for those who already have." — Mick Chomyn, General Manager & Lean Project Coordinator, Path Links Pathology Services
Amidst the plethora of resources on merging Lean and Six Sigma, this book details a logical alternative: a no-nonsense strategy for maintaining the best of both without diluting either. The authors lay out the differences between Lean and Six Sigma, define the power and focus of each, and detail why and how to use them in a synchronized complementary way. This practical, easy read shows how to pick the right projects, people, and toolsets to achieve bottom-line results faster. Readers will benefit from the authors' years of experience implementing Lean with Six Sigma, through detailed case studies from both manufacturing and service companies. Catalog no. PP7343, 2007, 192 pp., ISBN: 978-1-56327-343-8, $43.95 / £27.99
Six Sigma Fundamentals A Complete Introduction to the System, Methods, and Tools D.H. Stamatis “...a single, straightforward reference book, Six Sigma Fundamentals answers the Quality call all by itself. … If you can only have one book...this is it, not only for Six Sigma Green and Blackbelts, but also for anyone involved in the field of Quality.” — Janet MacDonald, Chair, American Society for Quality
With a focus on both manufacturing as well as non-manufacturing organizations, this book demystifies the Six Sigma methodology and provides the reader with a solid understanding of what defines a Six Sigma initiative. Each chapter fully addresses the concepts of the Six Sigma philosophy and explains the methodologies for real-world applications. Catalog no. PP7292, 2004, 368 pp., Soft Cover, ISBN: 978-1-56327-292-9, $55.95 / £35.99
Six Sigma Tool Navigator The Master Guide for Teams Walter J. Michalski Michalski provides a complete compendium of actual tools, definitions, and techniques needed to move your organization closer to producing minimal defects. It includes a collection of Six Sigma tool strings that allow teams to combine Six Sigma tools to accomplish a particular outcome. The book classifies each tool by process application, description of various applications, possible links to before and after tools, and problem-solving phases most applicable for the tool. In includes — • A comprehensive overview of 222 improvement tools covering benchmarking, cause and effect, control, FMEA, and process mapping • Over 70 tool string flow charts • A Six Sigma tools cross reference section • Comprehensive statistical tables • A CD-ROM containing a searchable version of the entire text Catalog no. PP7295, 2003, 768 pp., Soft Cover, ISBN: 978-1-56327-295-0, $82.95 / £52.99
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METHODS & TOOLS – TOTAL PRODUCTIVE MAINTENANCE The OEE Primer Understanding Overall Equipment Effectiveness, Reliability, and Maintainability D.H. Stamatis Assessing existing and new equipment from classical, reliability, and maintainability perspectives, this primer explores the overall effectiveness of machines and unveils novel methods that focus on design improvement—including hazard analysis, rate of change of failure (ROCOF) analysis, failure rate finite element analysis (FEA), and theory of inventive problem solving (TRIZ). It covers loss of effectiveness, electrical maintenance, Weibull distribution, measurement techniques, and mechanical and electrical reliability. The book also discusses Reliability and Maintainability (R&M), not as tools to be used in specific tasks, but as a discipline. It also considers the application of OEE as an overall improvement tool Includes a bonus CD with more than 100 pages of appendices and additional resources featuring statistical tables, outlines, case studies, guidelines, and standards Catalog no. K10723, June 2010, 502 pp., Soft Cover, ISBN: 978-1-4398-1406-2, $54.95 / £38.99
Uptime Strategies for Excellence in Maintenance Management, Second Edition John Dixon Campbell and James Reyes-Picknell "This is a significant and very welcome upgrade to what was already an important standard text. It should be required reading for all maintenance managers and those senior executives who want to understand the contribution of physical asset management to their business success." — Ben Stevens, President, OMDEC Inc.
In today's competitive marketplace, the flow of goods must not be hindered by avoidable obstacles such as maintenance downtime. This book provides insight into successful strategies for managers, maintenance, and non-maintenance professionals alike. It covers current trends in technology, reliability maintenance improvements, and the challenges of finding qualified maintenance personnel due to an aging labor force. In addition, it gives a thorough review of what it takes to achieve excellence in maintenance. In treating this technical topic, it links a variety of seemingly disparate and competing concepts into a single simple strategy. Catalog no. PP7335, 2006, 384 pp., ISBN: 978-1-56327-335-3, $49.95 / £31.99
TPM in Process Industries Tokutaro Suzuki Process industries have a particularly urgent need for collaborative equipment management systems, but until now have lacked for programs directed toward their specific needs. TPM in Process lndustries brings together top consultants from the Japan Institute of Plant Maintenance to modify the original TPM Development Program. In this volume, they demonstrate how to analyze process environments and equipment issues including process loss structure and calculation, autonomous maintenance, equipment and process improvement, and quality maintenance. For all organizations managing large equipment, facing low operator/machine ratios, or implementing extensive improvement, this text is an invaluable resource. Catalog no. PP7036, 1994, 416 pp., ISBN: 978-1-56327-036-9, $98.95 / £62.99
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METHODS & TOOLS – TOTAL PRODUCTIVE MAINTENANCE Autonomous Maintenance DVD Set Shopfloor TPM Implementation Productivity Press With Productivity's Autonomous Maintenance training, you'll learn how to unleash the hidden potential on your shopfloor and dramatically lower your production costs. The video takes you inside American companies that have successfully introduced autonomous maintenance. You hear managers, shopfloor maintenance workers and team leaders describing how it worked for them. Employees from both discrete manufacturing and the process industry share their methods and successes in implementing autonomous maintenance. Involving all your employees in maintenance activities will benefit your company, because the people who operate the machines on a daily basis understand the finer details of a machine's functionality. They can spot early signs of problems and save your company money by preventing costly repairs and long delays in the production process. In addition to the two hour DVD, the package includes a facilitator guide and participant guide. Visit the product description at our website for a free demonstration. Catalog no. PP7337, 2006, DVD (approx. 120 min.), ISBN: 978-1-56327-337-7, $2099.00 / £1337.00
Practical TPM Successful Equipment Management at Agilent Technologies James Leflar Replete with annotated photographs and illustrations documenting Agilent's successful program, this book offers an invaluable roadmap to TPM implementation. Drawing on his experience at Agilent, the author explains the fundamental concepts of TPM, including the six basic principles, goals, cultural changes that result from TPM, and keys to successful implementation. He describes, in step-by-step detail, the evolution of Agilent’s TPM program, clearly defining and demonstrating each phase. The book focuses on developing a vision and a strategy for successful TPM programs. It includes master checklists, forms, and appendices with examples of maintenance training materials. Catalog no. PP7242, 2001, 384 pp., ISBN: 978-1-56327-242-4, $59.95 / £38.99
Autonomous Maintenance in Seven Steps Implementing TPM on the Shop Floor Fumio Gotoh and Masaji Tajiri Illustrated with examples from Toyota, Asai Glass, Bridgestone, Hitachi, and other top companies, this book comprehensively covers all seven steps of autonomous maintenance (AM). It provides an overview of AM features and checklists for step audits to certify team achievement at each step. The author discusses Total Productive Maintenance (TPM) basics such as the six big losses, overall equipment effectiveness (OEE), causes of losses, and six major TPM activities. He includes an implementation plan for TPM and five countermeasures for achieving zero breakdowns, useful guidelines and case studies in applying AM to manual work such as assembly, inspection, and material handling. Catalog no. PP7219, 1999, 352 pp., ISBN: 978-1-56327-219-6, $55.95 / £35.99
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For those who are tired of just talking about health care reform Adopting the principles and practices of the Toyota Production System, Virginia Mason has moved from the red into the black while improving on all measures of patient care.
22 age p e Se At the newly improved Virginia Mason Medical Center: • Nurses now spend 90 percent of their time in direct patient care • Liability insurance costs have dropped by over a third • Rates of central line infections, injurious falls, and surgical site infections are now some of the lowest found anywhere • Profits are strong enough that all staff receive bonuses
While the journey is not an easy one, it is possible for any medical facility to transition itself to one that delivers superb medical care while at the same time controlling costs. And more and more are coming to Virginia Mason to find out how…
Catalog no. PPCAT
Encouraging an overdue shift in thinking, this book gives managers and executives the means to maximize employee potential by first showing them how to increase the improvement power of their HR departments. See page 33.
Integrating traditional approaches in Lean, Sigma Six, and CQI with new approaches, tools, and perspectives, this book facilitates the effective management of the complexities and dynamics unique to health care operations. See page 30.
Expand your View on Lean
Dept C35 270 Madison Avenue, 4th Floor New York, NY 10016 Mailroom Please route to: c V.P. Manufacturing c Plant/Production c Manager c TPM Manager
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