LEI Workbook Set

This workbook explains in simple, step-by-step terms how to introduce and sustain lean flows of material and information in pacemaker cells and lines, a prerequisite for achieving a lean value stream.

A sight we frequently encounter when touring plants is the relocation of processing steps from departments (process villages) to product-family work cells, but too often these "cells" produce only intermittent and erratic flow. Output gyrates from hour to hour and small piles of inventory accumulate between each operation so that few of the benefits of cellularization are actually being realized; and, if the cell is located upstream from the pacemaker process, none of the benefits may ever reach the customer.

This sequel to Learning to See (which focused on plant level operations) provides simple step-by-step instructions for eliminating waste and creating continuous flow at the process level.

Creating Level Pull shows you how to advance a lean manufacturing transformation from a focus on isolated improvements to improving the entire plantwide production system by implementing a lean production control system.

"The workbook is unique because it is a step-by-step case study on how to implement a level, pull-based production control system,” says author Art Smalley. "This is a new step towards ‘system kaizen that is not yet well understood outside of Toyota."

For the tens of thousands of users of value-stream mapping at the facility level, Seeing the Whole Value Stream provides the logical next step, extending the field of view all the way up and down the value stream. Dan Jones and Jim Womack, co-authors of the best-selling Machine That Changed the World and Lean Thinking provide a management tool for identifying and removing waste along the entire value stream from raw materials to end customer. This expanded second edition of the original book Seeing the Whole also provides real-world case studies.

Making Materials Flow describes in plain language another step in implementing a complete lean business system by explaining how to supply purchased parts to the value stream in order to support continuous flow.

Value-stream maps are the blueprints for lean transformations and Learning to See is an easy-to-read, step-by-step instruction manual that teaches this valuable tool to anyone, regardless of his or her background.

This groundbreaking workbook, which has introduced the value-stream mapping tool to thousands of people around the world, breaks down the important concepts of value-stream mapping into an easily grasped format. The workbook, a Shingo Research Prize recipient in 1999, is filled with actual maps, as well as engaging diagrams and illustrations.

This workbook explains step-by-step a comprehensive, real-life implementation process for optimizing your entire fulfillment stream from raw materials to customers, including practical insights into two critical concepts: calculating the total cost of fulfillment and collaborating across all functions and firms along the fulfillment stream.