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A3s (18) Show All »
Welcome to the MTL A3 Dojo
By: Shook, John | February 9, 2011
A3s; Columns
Welcome to this MTL-mini site within www.  lean.  org a destination for thought leadership in lean management in general, "managing to learn" and the A3 process in particular.  The goal of this site is to narrow the gap between reading about how to create an A3 and actually doing A3 management. This site within a site is meant to be a shared space for A3 thinking, a place for you to engage with others on the nitty-gritty daily challenges of your specific problems. Even for you to create an A3 and own it in the process.  This mini-site emerged out More »
A3 Template
By: Sobek, Durward | January 16, 2010
A3s; Forms and Templates
Thanks to Associate Professor Durward Sobek, Mechanical and Engineering Dept.  , Montana State Univ.  , for sharing this A3 template and illustration of an improvement cycle for using it. More »
Audio (18) Show All »
Forward to Fundamentals Webinar with Jim Womack and John Shook
By: Shook, John; Jim Womack | April 23, 2009
Audio; Videos and Webinars
In recent years, most discussions around lean transformation have understandably evolved toward more managerial and strategic matters. Yet there remains an alarming lack of solid implementation of the fundamentals! In this current economic crisis we can actually move our lean journeys forward faster by looking back to the lessons that led to the creation of TPS in the weakened Japanese economy following World War II. This webinar is designed to uncover the deep roots of the original lean thinking and tools and how you can better focus your own lean implementation plans and execution.  This webinar features Jim Womack, Chairman More »
Lean Thinking, Second Edition (Audiobook - CD)
By: James P. Womack and Daniel T. Jones | March 2, 2003
Audio; Books
Are the calls for making the lean leap falling on deaf ears in the boardroom? Just slip this audio CD of the Lean Thinking onto the boss’s home stereo to get the message across subliminally. Then get out of the way when the boss comes to work and rushes onto the shop floor to lead kaizen workshops. More »
Case Studies (39) Show All »
Sustain Your Lean Business System with a “Golden Triangle”
By: Marchwinski, Chet | April 1, 2014
When medical device maker Phase 2 fought off an overseas challenge by meeting the global price, margins took a big hit. With help from customer Medtronic Advanced Energy, the company rebuilt margins by lifting its lean operating system to a higher level and keeping it there with a "golden triangle" of sustainability. More »
Cultivating a Lean Problem-Solving Culture at O.C. Tanner
By: Bartholomew, Doug | January 22, 2014
O.  C. Tanner is in the appreciation business. It develops employee reward and recognition programs and manufactures a wide variety of emblems, rings, trophies, and other custom products that complement the programs. And if you are in the appreciation business, you have to live it in your own workplace. For O.  C. Tanner that meant a lean transformation had to show the company appreciated and wanted people’s problem-solving ideas. Here’s a report on that effort, including what worked and what didn’t. More »
Columns (274) Show All »
The Designer's Dilemma
By: Durward Sobek | September 23, 2014
Durward Sobek unpacks the "designer’s dilemma"—the situation wherein you have the MOST freedom to make decisions when you know the LEAST about the problem. Learn how set-based innovation and trade off curves can help. More »
How to Make Your Supplier Your Lean Partner
By: Randy J. Dobbs | September 19, 2014
Lean practitioner Randy Dobbs says working with suppliers to improve the extended value stream of his company has been one of the most rewarding aspects of his career. Read Dobbs' advice on how to work effectively with suppliers. More »
Events (12) Show All »
2014 Lean Healthcare Transformation Summit
January 10, 2014
June 4-5, 2014 - Los Angeles, California. Two days when you can learn directly from the lean healthcare leaders who are making real change and getting real results in how we deliver and pay for healthcare. More »
2014 Transformation Summit
October 21, 2013
March 5-6, 2014 - Orlando, Florida. Improve the work, develop the people - the building blocks for continuous innovation. More »
Presentations (49) Show All »
Lean Startup: From Toyota City to Fremont to You
By: Shook, John | February 10, 2014
Speaking at the 2013 Lean Startup Conference, John Shook, CEO of the Lean Enterprise Institute, used his slides to give the audience some background on lean’s development and its key concepts. But he also noted that whether a company is a startup or an established company, lean thinking and practice means:Engage Everyone in Problem Finding and Continuous ExperimentationGive Everyone Permission to Fail and Ability to Succeed More »
Managing on Purpose
By: Shook, John | February 10, 2014
John Shook, CEO of the nonprofit Lean Enterprise Institute, introduces a lean transformation “house” or model that uses five key questions to customize the transformation to a company’s business situation.   Shook believes too many companies defaulted into a prescriptive transformation model by simply trying to copy the tools and techniques in the classic Toyota Production System house that has been around for 40+ years. John will talk about the model at the 2014 Lean Transformation Summit. More »
Workshops (55) Show All »
A Factory of One: Applying Lean Thinking to Improve Your Personal Performance
As lean moves out of the "tool age," leaders—managers, directors, executives— must invest more time in the critical work of lean leadership: going to the gemba to support value creators in their improvement work and coaching and mentoring teams to develop their problem solving capabilities. This ensures that all organizational processes continuously add value to customers. More »
A Factory of One: Applying Lean Thinking to Improve Your Personal Performance (Online Webcast)
This workshop will help leaders understand how three lean concepts – standard work, flow and visual management - can be applied to the gemba of an individual knowledge worker to make communication more effective and less burdensome. It will enable leaders at all levels to focus on value creation rather than becoming more efficient at Management of non-value-creating activities. The workshop will show leaders how they can do their work quicker and with better quality so that they can spend more time at the gemba coaching and mentoring those who work in value—creating roles. More »
Articles (681) Show All »
Lean Success Stories
By: Marchwinski, Chet | May 16, 2014
The following examples of lean management principles in action show how a variety of businesses and organizations applied lean principles to solve real business problems under diverse business conditions. We’ve arranged them in 16 categories to help you find the examples you need.  Be sure to read LEI’s complementary Senior Executive Series on Lean Leadership to find out how many of the executives who took part in these case studies changed who they managed and led. More »
Teaching Lean Accounting with a Manufacturing Simulation
March 26, 2014
The paper “Teaching Lean Accounting with a Manufacturing Simulation” was created to introduce college and graduate students to Lean Accounting principles. But you may find its explanations and simulation effective for showing finance and accounting professionals how traditional management accounting systems encourage behavior in conflict with lean by rewarding overproduction.  It won honorable mention in 2012 for the AICPA/Mark Chain Award for Graduate Teaching Innovation. The authors also received the Lean Enterprise Institute’s Excellence in Lean Accounting Awards for separate achievements in advancing lean accounting.  Learn more about what lean accounting is, is not, and how to start implementing it More »
Books (184) Show All »
Lead With Respect: A Novel of Lean Practice
By: Michael Ballé and Freddy Ballé | July 28, 2014
"Lead With Respect is a terrific book that puts the elements of genuine motivation into a broader context and helps leaders translate those principles into action.  "—Daniel H. Pink, author of TO SELL IS HUMAN and DRIVE"The Ballé books are a great way to get started or to speed up your pace of transformation, personal and organizational.  "—Jim Womack, Founder of Lean Enterprise InstituteIn their new business novel Lead With Respect, authors Michael and Freddy Ballé reveal the true power of lean: developing people through a rigorous application of proven tools and methods. And, in the process, creating the only sustainable source of competitive advantage—a culture More »
Lead With Respect: A Novel of Lean Practice
By: Michael Ballé and Freddy Ballé | July 28, 2014
"Lead With Respect is a terrific book that puts the elements of genuine motivation into a broader context and helps leaders translate those principles into action.  "—Daniel H. Pink, author of TO SELL IS HUMAN and DRIVE"The Ballé books are a great way to get started or to speed up your pace of transformation, personal and organizational.  "—Jim Womack, Founder of Lean Enterprise InstituteIn their new business novel Lead With Respect, authors Michael and Freddy Ballé reveal the true power of lean: developing people through a rigorous application of proven tools and methods. And, in the process, creating the only sustainable source of competitive advantage—a culture More »
Charts, Graphs and Diagrams (4) Show All »
Begin from Need
October 28, 2010
"Begin from need" is attributed Taiichi Ohno, a key developer of the Toyota Production System. It means, as shown on these charts, what does the customer (the organization, the worker, the gemba) need right now? It's  another way of articulating the principle of PDCA, plan-do-check-act.    It helps us begin problem solving by grasping the situation, and avoid jumping to conclusions. More »
Toyota Production System House
By: Marchwinski, Chet | June 5, 2009
The Toyota Production System "house" shows the elements of a lean system. Source: Lean Lexicon. More »
eLetters (344) Show All »
How should I accelerate my own learning?
By: Ballé, Michael | September 22, 2014
Columns; eLetters
Dear Gemba Coach,How should I accelerate my own learning? More »
Would you have a fresh perspective on 5S to make it more motivating?
By: Ballé, Michael | September 10, 2014
Columns; eLetters
Dear Gemba Coach,I’m the manager of a plant that has changed hands (again). The new corporate team finds my 5S insufficient (again) and want me to make a 5S drive (again). Would you have a fresh perspective on 5S to make it more motivating? More »
Forms and Templates (18) Show All »
Standardized Work Chart
December 6, 2012
The standardized work chart shows operator movement and material location in relation to the machine and overall process layout. It should show takt time, work sequence, and standard WIP.  The standardized work chart is one of the three basic forms for creating standardized work, along with the standardized work combination table and job instruction sheet. The purpose of standardized work, according to Kaizen Express from which this form is taken, is to provide a basis for continuous improvement through kaizen.  Kaizen Express, from which this example is taken, is a concise, precise illustrated guide to the fundamentals of the Toyota More »
Standardized Work Combination Table
December 6, 2012
The standardized work combination table shows the combination of manual work time, walk time, and machine processing time for each operation in a production sequence. This form is a more precise process design tool than the Operator Balance Chart. It can be very helpful to identify the waste of waiting and overburden, and to confirm standard work―in―process.  The standardized work combination table is one of three basic forms for creating standardized work, along with the standardized work chart and job instruction sheet. The purpose of standardized work, according to Kaizen Express from which this form is taken, is to provide More »
Videos and Webinars (37) Show All »
The Lean Transformation Model
By: Lean Enterprise Institute | January 21, 2014
John Shook, CEO of the Lean Enterprise Institutes explains the Lean Transformation Model and how it can transform your organization. More »
Kaizen vs. the Suggestion Box
October 25, 2012
Mark Graban’s new book, Healthcare Kaizen (Productivity Press), co-authored with Joe Swartz, has lots of examples and practical advice for involving front-line staff with installing and sustaining a continuous improvement system. More »