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How To Implement Lean Manufacturing, by Lonnie Wilson
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A Practical, Hands-on Guide to Lean Manufacturing
This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made.
How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to:
- Rigorously test and retest the state of your "leanness" with unique evaluators
- Develop and deploy plant-wide strategies and goals
- Improve speed and quality and dramatically reduce costs
- Reduce variation in the manufacturing system in order to reduce inventory
- Reduce lead times to enable improved responsiveness and flexibility
- Synchronize production and supply to the customer
- Create flow and establish pull-demand systems
- Perform system-wide and specific value-stream evaluations
- Generate a comprehensive list of highly focused Kaizen activities
- Sustain process gains
- Manage constraints and reduce bottlenecks
- Implement cellular manufacturing
- Sales Rank: #735506 in Books
- Published on: 2009-09-01
- Original language: English
- Number of items: 1
- Dimensions: 9.50" h x .98" w x 7.60" l, 1.67 pounds
- Binding: Hardcover
- 336 pages
About the Author
Lonnie Wilson has been teaching and implementing Lean techniques for over 39 years. His experience spans 20 years with an international oil company where he held a number of management positions. Then in 1990 he founded Quality Consultants which teaches and applies Lean techniques to not only small entrepreneurs but also Fortune 500 firms, principally in the United States, Mexico and Canada.
Most helpful customer reviews
22 of 23 people found the following review helpful.
Recommended to Those Wanting to Apply Lean Techniques
By RKooiman
An industrial contractor once told me that he really liked the fact that companies were trying to apply Lean because he got a lot of work as a fallout of poor application.
It's amazing to me that companies will try to adopt state-of-the-art manufacturing concepts, such as Lean, without a good understanding of what they hope to accomplish or even why the concepts have become popular.
I think part of the reason is that there is not much useful, practical advice on how to do it.
This book goes a long way toward filling that void.
It is loaded with practical examples and exercises to clarify the application methods and benefits. It has some suggestions on getting started that can make you money almost immediately.
Chapters 2-5 provide a good overview (and there is a glossary for quick reference). Chapters 6-8 give a step-by-step procedure for getting started. Other chapters explain how to advance a process already in place and several chapters have excellent case examples. I especially liked chapter 18 where there is a simple experiment with dice to show the effect of variation on plant capacity.
I very much enjoyed reading this book because it helped me understand the principles and how to apply them. I was also impressed with how much the case studies reinforced the principles and tied them to real events. I recommend it to those who wish to implement lean in their facility.
10 of 10 people found the following review helpful.
Outstanding Practical Guide to Lean Manufacturing!
By William B.
If you have read "LEAN THINKING" by James P Womack and Daniel T. Jones, you may have been left wondering what Lean Manufacturing and the Toyota Production System was all about. It may have seemed mysterious and not well defined. Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING" is a guidebook to Lean Manufacturing that will take the mystery out of process for you. It is a practical HOW-TO guide that can be used by plant managers, executives, quality managers and production personnel to implement the Lean Systems within their facilities.
This book not only addresses the strategy on how to implement Lean Manufacturing but also addresses cultural change necessary for a successful transformation. In the end you have to sustain the gain and the book tells you what is necessary.
What makes this book standout from other Lean texts is that the book itself is written in a Lean style of writing. Lonnie uses "Points of Clarity" to highlight important concepts within the book. Additionally he uses hundreds of visual graphics and tables that draw the reader's attention. Visual clues and organization is a key concept in Lean. I don't think you can turn two or more pages without being grabbed by a new visual to help make a point in the book.
I was impressed with the level of practical detail. Need to calculate OEE or the proper KANBAN size? Does Value Stream Mapping have you confused? The book provides the formula's necessary. It places these concepts in context to the big picture of efficiency, lead-time or cycle-time reduction. The book is filled with personal examples from Lonnie Wilson's career leading transformation efforts. Case studies are also given to drive home and follow the complete process of a successful Lean project and some that are not so successful.
This is a book I would personally recommend to anyone getting ready to attend a Lean training workshop. Read this book first and you will be prepared for your class. As a university instructor, I like to tell my students, "The answer is in the book". I think you will find many insightful answers about Lean in Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING".
7 of 7 people found the following review helpful.
A practical approach to implementing lean manufacturing
By Craig Matteson
Lonnie Wilson teaches you how to implement the best aspects of lean manufacturing without having to implement the cultural aspects of the Toyota Production System. He believes that cultural transformation, while a benefit if you can pull it off, keeps you from realizing he benefits of Lean quickly, is risky, and adds cost to your Lean project.
Chapter 1 explains his views along these lines and Chapter 2 is a look at Toyota's System and why you need a manufacturing system that focuses on behavior more than culture. Chapter 3 shows you why variation gets in the way of your manufacturing goals and how inventory masks and is the result of variation. You want to eliminate inventory and you have to eliminate variation in order to eliminate the need for inventory. Chapter 5 shows you why Lead Time exists and how you can reduce it.
Chapter 6 discuses the basics of Cultural Change and how need to start thinking about Lean and your manufacturing culture. Chapter 7 looks at strategic approaches you can take to becoming a Lean Manufacturing environment and shows you what Takt is and how to use it. You also get a look at what a basic time study is and how to conduct a balancing study. Spaghetti Diagrams and Value Stream Mapping are also discussed.
Chapter 8 takes you through a Lean implementation process while chapter 9 looks at how to do Lean planning and how to set appropriate and achievable goals. Chapter 10 shows you how to maintain the gains you worked so hard to make and chapter 11 looks at the effect of your culture on Lean and how to think about what you can do with your own.
Chapters 12 and 13 deal with managing your constraints and the benefits you can realize by using cellular manufacturing. Chapter 14 is a case study on cultural change and chapter 15 is a case study on early gains realized by reducing lead times. Chapter 16 is three small case studies as good examples of what to do. Chapter 17 looks at what happens when Lean is used poorly. The last three chapters show you how to conduct your own experiments on variation and inventory, a bunch of assessment tools you can use, and a summary of how your company can become a house of Lean.
This is, I believe, a useful and practical book. Heaven knows, we need to become even more competitive to hold onto as many manufacturing jobs as we can. Maybe someday we can once again grow our manufacturing base. But if we ever do, it will be because we have become globally competitive not because of some series of spending initiatives out of Washington D.C..
Reviewed by Craig Matteson, Ann Arbor, MI
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