Gemba Kaizen A Commonsense Approach to a Continuous Improvement Strategy

ISBN-10: 0071790357
ISBN-13: 9780071790352
Edition: 2nd 2012
Authors: Masaaki Imai
List price: $42.00 Buy it from $24.05
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Description: The long-awaited, thorough update of the definitive work on one of the most popular improvement methods, Gemba KaizenGemba Kaizen: A Commonsense, Low-Cost Approach to Management, Second Edition is an in-depth revision of this renowned, bestselling  More...

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Book details

List price: $42.00
Edition: 2nd
Copyright year: 2012
Publisher: McGraw-Hill Professional Publishing
Publication date: 6/13/2012
Binding: Hardcover
Pages: 448
Size: 6.25" wide x 9.00" long x 1.25" tall
Weight: 1.958
Language: English

The long-awaited, thorough update of the definitive work on one of the most popular improvement methods, Gemba KaizenGemba Kaizen: A Commonsense, Low-Cost Approach to Management, Second Edition is an in-depth revision of this renowned, bestselling guide. The book is now expanded with 50% new material, including specific case studies tracking success stories from a wide variety of industries and practitioners worldwide. Since its publication by McGraw-Hill in 1997, the book has introduced the concepts of Kaizen to hundreds of thousands of people and their companies as they search for ways to survive and prosper. This trend will only grow amid increasingly intense global competition.Masaaki Imai is a leading authority in the field—the man who introduced the concepts of Kaizen to the English-speaking world. Fourteen years since the publication ofGemba Kaizen, the world sees the wide application of Gemba Kaizen going far beyond its manufacturing origins, and now carried into hospitals, government offices, hotels, ports, retailers, mining operations, software development, construction, and even universities. The Kaizen Institute, the consulting firm founded by Masaaki Imai, is at the forefront of this movement to adopt and promote Gemba Kaizen around the world. This new edition features global case studies from a wide range of sectors, sharing the keys to successful implementation of Gemba Kaizen.Gemba Kaizen: A Commonsense, Low-Cost Approach to Management, Second EditionFeatures current case studies, a new foreword, and 50% new materialExplains the original, clear, and correct meaning of Gemba Kaizen and how to apply it in practiceShows how Gemba Kaizen reduces cost, improves quality, and increases customer satisfactionGives relevant global examples in a wide variety of industries and applicationsShows how Gemba Kaizen is used in conjunction with aspects of Six Sigma, Lean Manufacturing, and other methodologies to achieve continuous improvementIncludes success stories from various industries, both public and private, and from industrialized and developing nations

Preface
Acknowledgments
About Kaizen Institute
An Introduction to Kaizen
Major Kaizen Concepts
Kaizen and Management
Process versus Result
Following the PDCA/SDCA Cycles
Putting Quality First
Speak with Data
The Next Process Is the Customer
Major Kaizen Systems
Total Quality Control/Total Quality Management
The Just-in-Time Production System
Total Productive Maintenance
Policy Deployment
The Suggestion System
Small-Group Activities
The Ultimate Goal of Kaizen Strategy
Gemba Kaizen
Gemba and Management
The House of Gemba
Standardization
The Five S (5S) of Good Housekeeping
Muda Elimination
The Golden Rules of Gemba Management
Go to the Gemba First
Check the Gembutsu
Take Temporary Countermeasures on the Spot
Find the Root Cause
Standardize to Prevent Recurrence
Application of the Golden Rules
Quality, Cost, and Delivery at the Gemba
Quality: More Than Just a Result
Quality Management at the Gemba
Cost Reduction at the Gemba
Improve Quality
Improving Productivity to Lower Costs
Reduce Inventory
Shorten the Production Line
Reduce Machine Downtime
Reduce Space
Reduce Lead Time (Throughput Time)
Role of the Gemba in Overall Cost Reduction
Delivery
Quality Improvement and Cost Reduction Are Compatible
Standards
Maintain and Improve Standards
Operational Standards
Key Features of Standards
Toyoda Machine Works
The Kaizen Story
The Toyota Business Practice: The Standard Problem-Solving Story at Toyota
Kaizen and International Quality Standards
The 5S: The Five Steps of Workplace Organization
Good Housekeeping in Five Steps
5S for the City: Civic Pride in Romania
A Detailed Look at the Five Steps of 5S
Seiri (Sort)
Seiton (Straighten)
Seiso (Scrub)
Seiketsu (Systematize)
Shitsuke (Standardize)
Introducing 5S
Muda
Muda of Overproduction
Muda of Inventory
Muda of Defects
Muda of Motion
Muda of Processing
Muda of Waiting
Muda of Transport
Muda of Time
Categorizing Muda in the Service Sector
Muda, Mura, Muri
Mura (Variation)
Muri (Overburden)
Removing Muda from Public-Sector Organizations
The Foundation of the House of Gemba
A Learning Enterprise
Suggestion System and Quality Circles
Building Self-Discipline
Visual Management
Making Problems Visible
Staying in Touch with Reality
Visual Management in the Five Ms (5M)
Manpower (Operators)
Machines
Materials
Methods
Measurements
Visual Management to Manage Complexity
Visual Management with 5S
Posting Standards
Setting Targets
The Supervisors' Roles in the Gemba
Training Within Industries
Managing Input (Manpower, Materials, and Machines)
A Day in the Life of a Supervisor at Toyota Motor Manufacturing Kentucky
Morning Market (Asaichi)
Best-Line Quality-Assurance Certification
Defining Challenges
Pseudomanagerial Functions of Supervisors in the Gemba
Gemba Managers' Roles and Accountability Kaizen at Toyota Astra Motor Company
Role Manuals at TAM
TAM Group Leaders' Responsibilities
TAM Foremen's Responsibilities
TAM Supervisors' Responsibilities
Items That Need to Be Managed in the Gemba
Group Leaders' Daily Schedule of Activities: Examples from the TAM Manual
Group Leaders' Activities: Production, Cost, and Quality Examples from the TAM Manual
Foremen's Activities: Cost-Reduction Examples from the TAM Manual
Supervisors' Activities: Personnel and Training Examples from the TAM Manual
Section Managers' Roles and Accountabilities: Examples from the TAM Manual
The Conditions Necessary for Successfully Defining Roles and Accountability at TAM
Staff Development
On-the-Job Training
Formal Classroom Training
Voluntary Activities
The Identification of Potential Problems
Hiyari Reports
Training in the Anticipation of Problems
The Benefits of Kaizen at Toyota Astra Motor Company
From Just-In-Time to Total Flow Management
Just-In-Time at Aisin Seiki's Anjo Plant
Takt Time versus Cycle Time
Push Production versus Pull Production
Establishing Production Flow
The Introduction of JIT at Aisin Seiki
The First Step of Kaizen at Aisin Seiki
The Second Step of Kaizen at Aisin Seiki
Spreading the Benefits of JIT to Other Industries
Total Flow Management
TFM Transformation in Company A
Just-In-Time at Wiremold
The CEO's Role in Kaizen
Going to the Gemba
Gemba Kaizen and Overall Corporate Kaizen Two-Day Kaizen
Checklists as a Kaizen Tool
Gemba Kaizen Workshops
Case Studies
Lessons from a 20-Year Kaizen Journey
Changing the IT Culture at Achmea
Daily Kaizen at Tork Ledervin
Kaizen in Public Spaces: Transforming Rome's Airports
Sonae MC: The Silent Revolution
Surpassing Expectations through Kaizen at Embraco
Kaizen at Oporto Hospital Centre: Making Patient-Centric Care A Reality
Kaizen Enables Innovation and Customer Intimacy at Densho Engineering
Kaizen Enables Innovation and Customer Intimacy
Cutting Red Tape at a Public Utility: Enexis
People Power: Participation Makes the Difference for Electrical Manufacturer in China
Rossimoda: Kaizen and Creative Product Development
Finsa Uses Kaizen to Emerge Stronger from a Crisis
Innovating with Kaizen at Group Health
Kaizen Helps Caetano Bus Deliver on Schedule
Kenyan Flour Producer Uses Kaizen to Increase Capacity, Improve Efficiency
Kaizen as the Foundation for Innovation at Medlog
Growing with Kaizen at Supremia
Exceeding Customer Expectations at Walt Disney World
Kaizen Experience at Alpargatas
Transforming a Corporate Culture: Excel's Organization for Employee Empowerment
Quality in a Medical Context: Inoue Hospital
The Journey to Kaizen at Leyland Trucks
Tightening Logistics at Matarazzo
Stamping Out Muda at Sunclipse
Housekeeping, Self-Discipline, and Standards: Tokai Shinei Electronics
Solving Quality Problems in the Gemba: Safety at Tres Cruces
Glossary
Index
Worldwide Contact Information for Kaizen Institute Consulting Group

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