Description
Book SynopsisThis book provides a step-by-step guide to implementing lean at SMEs using an approach that has been tested and fine-tuned at over a hundred organizations across India, South East Asia and the Middle East. The book approaches Lean through an implementation project cycle flow and enables the reader to understand the imperative for Lean, how to diagnose current operations, how to plan and deploy Lean and shows a path for long-term sustenance.
Diverse situations such as meeting the demand fluctuations, designing a facility, or improving profit margin etc. are included in the case studies from multiple sectors, to ensure that every reader finds a situation similar to their organizational situation. While the publicly available literature on lean offers a large collection of tools and techniques, given each organization’s unique context, the choice of the right sequence of tools differ. The book offers guidelines in terms of which solutions work in which context, backed by real-cases, which is a big help to the resource constrained SMEs. This book is an equally good resource for the organizations that have already implemented lean, as it provides realistic pointers about sustaining, tackling supply chain uncertainties and going beyond Lean by integrating emerging technologies and management principles. It is an excellent resource for students and researchers studying this area and also for corporates, professionals and industry watchers.
Table of Contents MODULE I: INTRODUCTION
1. History of Lean Management
- Origination of Toyota Production System
- Adaptation by the Western world
- The competitive imperative and compelling value proposition
- Cross-linkage of chapters, cases and sectors
2. Lean Management Principles
- 14 principles of lean management
- Customer focus
- Understanding value and waste - Muda, Muri and Mura
- Culture of a lean enterprise
- Key Metrics
MODULE II: SMEs and Lean Management
3. Overview of Small and Medium Enterprises
- Definition and economic role
- Challenges and constraints, Ownership and Management styles
- Barriers and Enablers to Lean implementation
- Targeted Lean Interventions – NCMP Lean Cluster scheme in India, Similar programs in other countries
4. Generic Framework for Lean implementation
- The five stage Lean implementation framework ( Assessment, Create Flow, Enable and Support Flow, Standardize and Sustain)
- Approaches to implementation
· Problem Solving
· The Focused Improvement Workshop
· Advisory & Hand holding
- Pros & Cons – what works best when
MODULE III: IMPLEMENTATION
5. Commencing the Lean Journey - Diagnosis
- Understanding management goals and objectives
- Core Team formation – getting the buy-in
- Gemba walk and identification of sources of value
- Measuring the current state using tools & templates such as VSM, MFD, OEE etc.
- Measuring Key metrics; Industry-specific key attributes
6. Designing the Lean Intervention & Developing Project Plan
- Create a Lean Roadmap for the enterprise
- Prioritizing projects – The importance of quick wins
- Set-up project management organization – Lean Champions, Pillar Heads
7. Implementation
- Team formation & taking ownership
- Kick starting through Focused Improvement Workshops / Events
- Create Flow – Core concepts such as One piece flow, process and layout design
- Enable Flow – Lean tools including Cycle time reduction, line balancing, Pull systems (kanban) etc
- Support Flow through SMED, Problem Solving, Jidoka etc
- Validating results and updating standards
- Feedback from implementation to back to plan
MODULE IV: MONITORING & SUSTENANCE
8. Post-implementation Monitoring
- Causes and prevention of slip-back
- Post-implementation reporting
- Standardizing processes through tools such as 5S, Poka-Yoke, AM, & PM etc.
- Tools & Templates
9. Sustaining Lean
- Why Lean journeys often fail to sustain
- Building Continual Improvement culture through kaizen
- Periodic Lean Assessments
- Beyond Operations - Expanding lean to the rest of the organization
- Commitment of senior management
- Tools & Templates
MODULE V: ACHIEVING LEAN EXCELLENCE
10. Turbo charging lean
- Six Sigma
- Industry 4.0,
- Theory of Constraints
- Sustainability
11. Leveraging Lean to tackle uncertainty
- Increasing occurrence and intensity of supply chain disruptions
- Supply Chain Risk Management
- Extending lean to supply chain
- Lean and flexibility
- Extending lean principles to achieve supply chain resilience
Appendix – Detailed Case Studies
i. Animal Feed (process industry) – Company turnaround through Lean intervention
ii. White Goods - Commercial refrigerator manufacturer – Classic Lean journey Tactical to Strategic; implement in existing plant to designing a new plant)
iii. Restaurant (Service operations) – customer delight through service and a template to growth
iv. Electronic products (High-speed discrete manufacturing) – reducing costs and building in flexibility
v. Plastic toys – Lead Design for a new product and facility
vi. Bulk Drugs (Pharmaceuticals) – applying problem-solving techniques for targeted improvements
VIII. Agricultural Seed Processing – Lean approach for a highly seasonal industry
