The Psychology of Lean Improvements

Table of contents

1. Cover
2. Half Title
3. Title Page
4. Copyright Page
5. Table of Contents
6. Introduction
7. 1 The Psychology of Change
   1. Perception of Change
   2. Victimizing
   3. Letting Go
   4. Lean Is a Battlefield
   5. Cost–Quality–Delivery
      1. Cost
      2. Quality
      3. Delivery
   6. Changing Your Business Strategy for Lean
      1. Productivity
      2. Quality
      3. Inventory/WIP
      4. Floor Space Use
      5. Throughput Time
   7. Psychology of Metrics
8. 2 Leading the Lean Journey
   1. What Have We Done for Our Customers Today?
   2. Dangers of Not Going Lean in a Down Economy
      1. Business Is Good, Why Improve?
      2. Business Is Good, We Must Improve
      3. Business Is Poor, Why Improve?
      4. Business Is Poor, We Must Improve
   3. Changing into a Lean Leader
      1. Acknowledge and Involve Your Staff
      2. Provide an Environment in Which People Can Be Successful
      3. Do Not Humiliate Anyone Who Works for You
      4. Create an Environment Where Mistakes Are Okay
      5. Do Not Hide behind Your Position
      6. Be Approachable
      7. Admit Your Mistakes
      8. Listen in a Way That Encourages Employees to Talk to You
      9. Be Clear in Your Requests
      10. Stand behind Your People
      11. Be a Good Communicator
   4. Leaders
   5. Need an ROI
      1. Training
      2. Team Building
      3. People Development
      4. Strategic Planning
   6. World-Class Products Need World-Class Processes
   7. You Are the Creator of Your Business Reality
9. 3 The Psychology of Waste
   1. Psychology of Overproduction
   2. Psychology of Overprocessing
   3. Psychology of Motion and Transportation
   4. Psychology of Inventory
   5. Psychology of Defects
   6. Psychology of Waiting
   7. Psychology of Human Potential
      1. “I’m Paid by the Hour”
      2. No Investment in the People
      3. People Are Expendable
   8. Psychology of Waste: Conclusion
10. 4 The Psychology of Dysfunction
    1. Misconception of Working Hard
       1. Speed!
    2. Living with Waste
       1. Living with Overproduction
          1. Setup
          2. Quality Problems
          3. Machines Issues
       2. Living with Motion
       3. Living with Transportation
       4. Living with Overprocessing
          1. Administrative Functions
          2. Extra Steps and Redundant Effort
          3. Inefficient Machines
          4. Inability to Identify a Completion Point
       5. Living with Defects
       6. Living with Waiting
       7. Living with Inventory
          1. Facility Space
          2. Production Process
11. 5 Making Change Happen with 5S
    1. 5S and Visual Control
       1. Sort
       2. Set in Order
          1. How to Make a Shadow Board
          2. Personal Tools: Dilemma or Solution?
          3. Tool Check Cards
          4. Right Sizing during Set in Order
          5. Examples of Right Sizing
       3. Shine
       4. Standardize
       5. Sustain
          1. Human Will
          2. End of the Cleanup Procedures
          3. Daily Walkthroughs
          4. 5S Audit
          5. 5S Tracking
          6. Incentives
    2. Psychology of 5S
12. 6 Making Change with Lean
    1. What Type of Manufacturer Are You?
       1. Process Based
       2. Assembly Line
       3. Cellular Manufacturing
       4. Inline Production
    2. Cellular and Inline Production
    3. Inline Production
    4. Total Productive Maintenance (TPM)
       1. 5S Maintenance
       2. Baseline Equipment and One-Turn Method
       3. Operator PM Requirements
          1. Proactive TPM
          2. Predictive TPM
       4. Maintenance Technician
       5. Visual TPM Boards
    5. Kanban and Material Replenishment
    6. Setup Reduction and Quick Changeover
       1. Layout
       2. Tool Placement
       3. Visual Setup Boards
       4. Material Handling
       5. Intermediate Jigs
    7. Visual Metrics and Performance
       1. Facility Performance
          1. Sales
          2. On-Time Delivery (OTD)
          3. Productivity
          4. Quality
          5. Safety
       2. Metric Communication Boards (Production)
       3. Production Control Boards
13. 7 Keeping the Lean Fire Going
    1. Goals
    2. Pay-for-Skill Program
       1. Number of Jobs
       2. Experience
       3. Attendance
       4. Kaizen and Kaizen Event Participation
       5. Quality Errors
    3. More Returns
    4. Lean Training Programs
    5. New Employee Training Programs
       1. Level 1: Company Product Overview Training
       2. Level 2: Quality Overview
       3. Level 3: Introduction to Lean Manufacturing
          1. Eight Wastes
          2. 5S and the Visual Workplace
          3. Standard Work
          4. Available Time
          5. Kaizen
       4. Level 4: Mock Line Training
    6. Cross-Training Program
       1. Levels of Progression
          1. Novice (N)
          2. Certified (C)
          3. Trainer (T)
       2. Temporary Worker Progression
    7. Training Managers and Engineers
       1. Managers
       2. Engineers
14. Conclusion
15. Glossary
16. Index