Lean Production. John Black

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      LEAN

      Production

      Implementing A World-Class System

      John Black

Copyright

       Library of Congress Cataloging-in-Publication Data

      Black, John R.

      Lean production : implementing a world-class system / John R. Black. —

      1st ed.

      p. cm.

      Includes bibliographical references.

      ISBN 978-0-8311-3351-1 (hard cover)

      1. Production management. 2. Production control. 3. Industrial productivity. I. Title.

      TS155.B5246 2008

      658.5—dc22

      2008010927

      Industrial Press, Inc.

      989 Avenue of the Americas

      New York, NY 10018

      First Edition, 2008

      Acquisitions Editor: John Carleo

      Managing Editor: Suzanne Remore

      Interior Text and Cover Design: Janet Romano

      Developmental Editor: Robert Green

      Copyright © 2008 by Industrial Press Inc., New York. Printed in the

      United States of America. All rights reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher.

      10 9 8 7 6 5 4 3 2 1

Dedication

      This book is dedicated to all the workers at Boeing, who work hard and never give up. I would like to express my thanks and appreciation to you all. As described in this book, we have traveled far and learned much on our road to world-class production. All of us, together, made and continue to make that progress possible. And The Boeing Company that we have worked to change and improve is not just today’s Boeing. It is a company that will last through all our lifetimes and those of our children as well.

      Table of Contents

       Cover

       Title Page

Copyright

Dedication

Introduction

Chapter 1: What is a Lean, World-Class Production System?

Chapter 2: Getting Lean — the Route to World-Class Production

Chapter 3: Japanese Roots — Toyota, Toyota, Toyota

Insight: Defects, Mistakes, and Inspections

Chapter 4: Building the Foundation — Employee Involvement and the Example of Boeing’s 757 Airplane Productivity Program

       Insight: The Boeing 737 Lean Story

       Chapter 5: Erecting the Roof — the Crucial Role of Leaders

       Insight: What a Great Leader Looks Like — the Selby Philosophy, the Staples Conversion, and the Mulally Factor

       Chapter 6: Promoting the Process — the Power of the Promotion Office

       Chapter 7: Japan Study Missions — the Power of Learning and Doing

       Chapter 8: Champions, Consultants, Sensei — the Differences and Their Key Roles

       Insight: About Inventory and Kanban

       Chapter 9: The Roadmap — Striving for Perfection Through Kaizen

       Insight: Implementation in a Small Company

       Chapter 10: Beyond Manufacturing — the Office and Service Industry Wasteland

       Insight: Lean Production in a Service Organization

       Summary: The Opportunity Is Yours to Choose

       Appendix I: Ten Lessons for a Lean, World-Class Production System

       Appendix II: Further Reading

       Glossary

       References

       About the Author

       Index

Introduction

      I have spent my 45-year career primarily in two fields: war and manufacturing. These endeavors are not so different as might be imagined. I have learned much about people and the way work is done, not only in two decades at Boeing and another decade as a management consultant, but also as part of an Army that was facing issues of education, motivation, and the successful or unsuccessful waging of war. My journey has taken me all over the world, and I believe that journey has formally concluded at the intersection of people, lean principles, and the Toyota Production System. Along the way, I have gained the understanding that striving for perfection is a way of life, one that applies equally to not only a lean, world-class production system, or to business in general, but also to every human endeavor, from war to the delivery of health care.

      My experience was won the hard way. After receiving СКАЧАТЬ