The Toyota Kaizen Continuum

Table of contents

1. Cover
2. Half Title
3. Title Page
4. Copyright Page
5. Table of Contents
6. Preface
7. The Author
8. 1 Introduction
   1. 1.1 Don’t Believe Everything That You Read in a Book
   2. 1.2 ABC’s of TPS
   3. 1.3 The Kaizen Continuum
9. 2 Foundational Elements of the Toyota Production System (TPS)
   1. 2.1 An Overview of the Toyota Production System (TPS)
   2. 2.2 Toyota’s Recent Turmoil
   3. 2.3 A History of the Toyota Production System (TPS)
   4. 2.4 Kentucky Alchemy
   5. 2.5 Keep It Simple
   6. 2.6 The Toyota Production System versus Lean Manufacturing
   7. 2.7 Standardization
      1. 2.7.1 Quest for the Cube
      2. 2.7.2 Visiting the Plant Floor
      3. 2.7.3 Understanding Standardized Work
   8. 2.8 Just In Time (JIT)
      1. 2.8.1 The Pull System
      2. 2.8.2 Flow Production
      3. 2.8.3 Takt Time
   9. 2.9 Jidoka
   10. 2.10 Continuous Improvement (Kaizen)
   11. 2.11 Developing the Tools
10. 3 Why the Toyota Production System Makes Sense: Common Sense
    1. 3.1 Common Sense 101
    2. 3.2 Understanding Value
    3. 3.3 Understanding Demand
    4. 3.4 Common Sense in Action
11. 4 Common Misconceptions and Misunderstandings Regarding the Toyota Production System
    1. 4.1 TPS Misconceptions and Misunderstandings
    2. 4.2 Which Way Is Best?
    3. 4.3 Toyota Production System Historical Overview
    4. 4.4 Kanban System Overview
    5. 4.5 The Toyota Way
    6. 4.6 The Customer Knows Best
    7. 4.7 Go. See. Act
12. 5 Waste Management … Improving the Manufacturing Process One Kaizen at a Time
    1. 5.1 Gap Management
    2. 5.2 The Three M’s
       1. 5.2.1 Muda
          1. 5.2.1.1 Transportation
          2. 5.2.1.2 Waiting
          3. 5.2.1.3 Overstock
          4. 5.2.1.4 Overproduction
          5. 5.2.1.5 Repair
          6. 5.2.1.6 Overprocessing
          7. 5.2.1.7 Non-Value-Added Work (NVAW)
       2. 5.2.2 Muri
       3. 5.2.3 Mura
    3. 5.3 Classification of Muda
       1. 5.3.1 Transportation
       2. 5.3.2 Waiting
       3. 5.3.3 Overstock
       4. 5.3.4 Overproduction
       5. 5.3.5 Repair
       6. 5.3.6 Overprocessing
       7. 5.3.7 Non-Value-Added Work (NVAW)
    4. 5.4 Muda Countermeasure Methods
    5. 5.5 Waste Elimination Example
13. 6 The Golden Rules of the Toyota Production System
    1. 6.1 Fundamentals
    2. 6.2 The Golden Rules of TPS
       1. 6.2.1 Simplify
       2. 6.2.2 Standardize
       3. 6.2.3 Specialize
    3. 6.3 Capital Investment Guidelines
       1. 6.3.1 Tangible Return on Investment Period
       2. 6.3.2 Recycle, Redeploy, and Reuse
       3. 6.3.3 Simple, Safe, and Reliable
14. 7 Cost Management for Profitability
    1. 7.1 Understanding the “Death Spiral”
    2. 7.2 Understanding the Cost Structure
       1. 7.2.1 Fixed and Variable Costs
       2. 7.2.2 Minimum Variable Costs
       3. 7.2.3 Break-Even Point
       4. 7.2.4 Managing Costs
       5. 7.2.5 Managing Cost Example
15. 8 Execution
    1. 8.1 Facing Reality
    2. 8.2 The Five-Step Process for Executing Improvement Initiatives
       1. 8.2.1 Assessment: Understanding the Business
       2. 8.2.2 Setting the Course
          1. 8.2.2.1 Identify the Project Leader
          2. 8.2.2.2 Completely Understand the Project Assessment …
          3. 8.2.2.3 Completely Understand the Project Target
          4. 8.2.2.4 Identify the Project Resources
          5. 8.2.2.5 Determine the Roles and Responsibilities
          6. 8.2.2.6 Develop the Plan
          7. 8.2.2.7 Completely Understand the Costs
          8. 8.2.2.8 Communicate
          9. 8.2.2.9 Execution
       3. 8.2.3 Rapid Implementation
       4. 8.2.4 Stabilization
       5. 8.2.5 Continuous Improvement
    3. 8.3 Conclusion
16. Index