1st Edition

Lean Execution The Basic Implementation Guide for Maximizing Process Performance

By Clifford Fiore Copyright 2016
    153 Pages 46 B/W Illustrations
    by Productivity Press

    153 Pages
    by Productivity Press

    Many books explain how to construct a value stream map, but few explain the process conditions and characteristics required to ensure a value stream map can be completed successfully. Lean Execution: The Basic Implementation Guide for Maximizing Process Performance fills this need.

    Although the book explains Lean methods and tools that maximize process performance, its main focus is on providing readers with detailed guidelines, process conditions, and helpful tips for ensuring successful implementation.

    Based on Clifford Fiore’s insights and experiences gained through years of firsthand application and implementation of Lean methods, the book supplies easy-to-understand explanations of proven Lean tools, methods, and concepts. For example, the concept of flow/theory of constraints is reviewed using a garden hose analogy.

    The text introduces material in a manner that mirrors the natural sequence for general implementation. It provides simple calculations, worksheets, and examples to reinforce the key concepts involved with determining production rates and process variation.

    In addition to explaining how to apply Lean tools correctly, the book provides the big picture perspective required to select and apply the appropriate Lean tool at the right time, while gaining helpful insight about the process under review. Sharing valuable lessons learned by trial and error, the book can help practitioners save valuable time and resources by not repeating similar mistakes.

    The book concludes with a summary that outlines a blueprint for maximizing success during implementation.

    Clifford Fiore has spent more than 30 years at a Fortune 500 company and is a recognized leader in applying Lean and Six Sigma methodologies. He is also a certified black belt and Lean expert. Through his work in adapting process improvement techniques in engineering, manufacturing, and the supply chain, he has emerged as an industry leader in implementing concepts towards reducing product cost, quality defects, and development cycle times.


    SECTION I: LEAN BASICS

    Lean Fundamentals
    Lean or Six Sigma?
    Lean History
    Lean Definition
    Flow
    Customer Value
    Waste Categories
    Push versus Pull Systems

    Value Streams and Value Stream Mapping
    Defining a Value Stream
    Mapping Considerations
    Process Considerations for Value Stream Mapping

    SECTION II: LEAN ASSESSMENT

    Lean Baseline Assessment
    Baseline Definition
    Baseline Overview
    Baseline Success Factors
    Baseline Execution

    Product Analysis
    Product Analysis Overview
    Time-Value Chart
    Spaghetti Diagram
    Communicating with Tools

    Operator Analysis
    Operator Analysis Overview
    Takt Time
    Line Balancing: The Problem
    Bottlenecks
    Garden Hose Analogy
    Line Balancing: The Solution
    Operator Process Variation
    Ergonomics

    Machine Analysis
    Machine Analysis Overview
    Overall Equipment Effectiveness

    SECTION III: LEAN IMPROVEMENT

    Five-S
    5S Overview
    5S Implementation

    Standard Work
    Defining Standard Work
    Standard Work Tools
    Adjusting Standard Work

    Cell Design
    Cell Definition
    Visual Systems
    Group Technology

    Process Improvement Enablers
    Setup Reduction
    Total Productive Maintenance
    Mistake-Proofing

    Materials Management
    Materials Management Overview
    Kanbans
    Little’s Law

    Knowledge Management
    Knowledge Management Overview
    Knowledge Management System

    General Guidelines for Lean Implementation
    Lean Perspective
    General Guidelines
    Lean Principles

    Appendix A: Using Six Sigma to Improve Product Quality

    Appendix B: Forms and Worksheets

    Appendix C: Glossary

    Appendix D: Answers

    References

    Index

    Biography

    Clifford Fiore

    "Lean Execution: The Basic Implementation Guide for Maximizing Process Performance provides a thorough, easily understandable, step-by-step ‘how-to guide’ with respect to implementing Lean activities in your organization that can be utilized as a training guide or as a concise refresher."
    —Michael S. Holmes, President, Cadence Aerospace, ADM Operations