Books I recommend to Help You on Your Lean Journey

Learning to See 

Much more important, these simple maps - often drawn on scrap paper - showed where steps could be eliminated, flows smoothed, and pull systems introduced in order to create a truly lean value stream for each product family.

In 1998 John teamed with Mike Rother of the University of Michigan to write down Toyota's mapping methodology for the first time in Learning to See. This simple tool makes it possible for you to see through the clutter of a complex plant. You'll soon be able to identify all of the processing steps along the path from raw materials to finished goods for each product and all of the information flows going back from the customer through the plant and upstream to suppliers. With this knowledge in hand it is much easier to envision a "future state" for each product family in which wasteful actions are eliminated and production can be pulled smoothly ahead by the customer.

Creating Continuous Flow

Winner of the 2003 Shingo Prize!

Creating Continuous Flow narrows the focus of Learning to See from the door-to-door value stream perspective to achieving true continuous flow at your critical pacemaker processes.

This new workbook explains in simple, step-by-step terms how to introduce and sustain lean flows of material and information in pacemaker cells and lines, a prerequisite for achieving a lean value stream. Creating Continuous Flow takes you to the next level in cellularization where you'll achieve even greater cost and lead time savings.

You'll Learn:

• Where to focus your continuous flow efforts
• How to create much more efficient cells and lines
• How to operate a pacemaker process so that a lean value stream is possible
• How to sustain the gains and keep improving

Making Materials Flow 

Creating Continuous Flow narrows the focus of Learning to See from the door-to-door value stream perspective to achieving true continuous flow at your critical pacemaker processes.

This new workbook explains in simple, step-by-step terms how to introduce and sustain lean flows of material and information in pacemaker cells and lines, a prerequisite for achieving a lean value stream. Creating Continuous Flow takes you to the next level in cellularization where you'll achieve even greater cost and lead time savings.

You'll Learn:

• Where to focus your continuous flow efforts
• How to create much more efficient cells and lines
• How to operate a pacemaker process so that a lean value stream is possible
• How to sustain the gains and keep improving

Creating Level Pull

Creating Level Pull shows you how to advance a lean manufacturing transformation from a focus on isolated improvements to improving the entire plant-wide production system by implementing a lean production control system. Lean efforts at most companies focus on point kaizen (e.g., reducing set up times, implementing 5S, etc.) that improves a small portion of the value stream running from raw materials to finished products. Or they focus on flow kaizen that improves the entire value stream for one product family. Creating Level Pull shows how companies can make the leap to system kaizen by introducing a lean production control system that ties together the flows of information and materials supporting every product family in a facility. With this system in place, each production activity requests precisely the materials it needs from the previous activity, and demand from the customer is leveled to smooth production activities throughout the plant. Creating Level Pull is written in plain English and walks you through the implementation process using a clear question-and-answer format, supported by diagrams, value-stream maps, and key formulas. Using a realistic example facility, the author shows you how to make the transition to a robust pull system. This involves answering a series of 12 critical questions including what items to hold in finished goods inventory and what items to make to order, how to buffer the system against instability, how to schedule batch processes, and how to level the production schedule. Careful attention to leveling (called heijunka) permits facilities to accommodate variations in demand with minimum inventories, capital costs, manpower, and production lead time.

The Machine that Changed the World

When The Machine That Changed the World was first published in 1990, Toyota was half the size of General Motors. Twenty years later Toyota passed GM as the world’s largest auto maker. This management classic was the first book to reveal Toyota’s lean production system that is the basis for its enduring success.

Authors Womack, Jones, and Roos provided a comprehensive description of the entire lean system. They exhaustively documented its advantages over the mass production model pioneered by General Motors and predicted that lean production would eventually triumph. Indeed, they argued that it would triumph not just in manufacturing but in every value-creating activity from health care to retail to distribution.

Today The Machine That Changed the World provides enduring and essential guidance to managers and leaders in every industry seeking to transform traditional enterprises into exemplars of lean success.

The Goal

30th Anniversary Edition. Written in a fast-paced thriller style, The Goal, a gripping novel, is transforming management thinking throughout the world. It is a book to recommend to your friends in industry - even to your bosses - but not to your competitors. Alex Rogo is a harried plant manager working ever more desperately to try improve performance. His factory is rapidly heading for disaster. So is his marriage. He has ninety days to save his plant - or it will be closed by corporate HQ, with hundreds of job losses. It takes a chance meeting with a professor from student days - Jonah - to help him break out of conventional ways of thinking to see what needs to be done. The story of Alex's fight to save his plant is more than compulsive reading. It contains a serious message for all managers in industry and explains the ideas, which underline the Theory of Constraints (TOC), developed by Eli Goldratt.