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Lessons from a Lean Consultant
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Table of Contents

Preface xvAcknowledgments xviiAbout the Author xixIntroduction xxiChapter 1: Case Study: How Lean Failed 1Gung Ho! 2Lean Training 2The First Kaizen Event 5Struggling with Change 9Raising the Bar: 5S Implementation 11Improving Work Instructions 12Lack of Accountability 13The Second Kaizen Event 14Giving Up on Lean 17End of the Journey 19Chapter 2: The Change Commitment 21The Three Main Drivers of Product Success 22The Big Picture 26The Strategic Purpose 28Creating Your Strategic Purpose 34Chapter Wrap-Up 41Chapter 3: The Lean Infrastructure: Kaizen 43Creating the Company Kaizen Program 44Kaizen Champion 44Kaizen Events 46Kaizen Steering Committee 53Kaizen Event Tracking and Scheduling 57Kaizen Event Communication 59Monthly Kaizen Meeting 63Getting Started 65Your First Kaizen Event 67Chapter Wrap-Up 70Chapter 4: Early Stumbling Blocks 715S and the Visual Workplace 72Time and Motion Studies 79Waste Removal 83Quality at the Source 87Workstation Design 89Chapter Wrap-Up 96Chapter 5: Operator and Supervisor Involvement 97Standard Work 98How to Get Them Involved 108Lean Manufacturing Training 111Chapter Wrap-Up 112Chapter 6: Lean Training Programs 113Training Programs for New Employees 113Cross-Training Program 121Training Managers and Engineers 127Chapter Wrap-Up 129Chapter 7: Lean Manufacturing as a Growth Creator 131Lean Goals 132Pay-for-Skill Program 133Number of Certifications 134Years of Experience 134Attendance 134Kaizen and Kaizen Event Participation 135Quality Errors 137Providing Incentives for Good Ideas 139Chapter Wrap-Up 140Chapter 8: Lean Leadership Made Simple 141Poor Leadership Traits 143The Master Delegator 143A More Congenial Leadership 145Effective Lean Leadership 149Chapter Wrap-Up 155Appendix A: Quick Reference 157The Seven Deadly Wastes 157Key Elements of a Company Kaizen Program 158Appendix B: Supplemental Material 1595S Audit Form 1595S Tracking Sheet 159Time Study Sheet 159Glossary 163Index 167

Promotional Information

Making Lean Work: "In-the-Trenches" Help from a World-Class ExpertLean manufacturing can improve productivity and quality, shorten lead times, reduce costs, and improve competitiveness. However, succeeding with lean is not easy. Chris A. Ortiz, one of the country's most respected lean implementers, shows you exactly how to overcome obstacles, drive value from lean, and sustain success for the long term.Ortiz draws on his experience leading many successful lean transitions and more than 150 kaizen events. He shows you how to prepare for a lean shop floor environment, implement best practice procedures and standards, build executive support, lead kaizen within the factory, and deal with the ups and downs you will inevitably encounter.Forget theory: This is a step-by-step, what-to-do guide for professionals in the trenches-plant and engineering managers, lean managers and directors, Six Sigma practitioners, and working engineers. Topics covered includeSeven reasons lean can fail-and how to overcome them Establishing successful kaizen programs: champions, events, teams, goals, tracking, and scheduling Avoiding early stumbling blocks in data collection, waste removal, and process design Getting your operators and supervisors to "buy into" lean Training managers, engineers, and new employees Promoting flexibility and cross-training Using lean to drive growth, not just save money Lean leadership made simple: twelve practical techniques, five simple rules-and ten things not to do Sample audit, tracking, and time study forms

About the Author

Chris Ortiz is a senior lean consultant and the owner of Kaizen Assembly. He has spent the majority of his professional career working for Fortune 500 companies, teaching and guiding them to become more efficient businesses. Chris has also led more than 150 kaizen events around the United States.Ortiz is also an instructor at five Washington state community and technical colleges. He has developed a reputation for delivering fast-paced, highly detailed, and interactive classroom-style courses.He is the author of the book Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line (Boca Raton, FL: Taylor and Francis Group, 2006). His lean implementation techniques have been featured in a variety of trade magazines, newspapers, corporate newsletters, Industrial Engineer magazine, Industrial Management magazine, and other lean manufacturing newsletters and periodicals.To contact Chris Ortiz, e-mail chrisortiz@kaizenassembly.com or go to his Web site, www.kaizenassembly.com.

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