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| Preface | |
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| Introduction | |
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| Revisiting Our Shop Floor | |
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| Beyond Taylorism | |
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| Making People Before Making Products | |
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| Addressing the Individual''s Needs | |
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| Genba-Oriented Thinking (Three Reals) | |
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| Developing a Genba-Oriented Mind | |
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| Learning from the Genba Experience | |
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| Transforming an Organization | |
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| Using Everybody''s Creative Power | |
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| Developing A Vision Of Shop Floor Excellence | |
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| Sailing in Today''s Business Environment | |
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| Changing Environment -- Past vs. Future | |
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| Our Vision | |
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| Creating an Organization with Self-Managed People | |
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| Ownership at the Source | |
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| Looking at Ourselves Straight in the Mirror | |
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| Achieving Excellence in Shop Floor Management (SFM)Controlling the Process | |
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| Traditional and Progressive Organizations | |
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| Developing a Progressive Organization | |
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| What We Should Work On | |
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| Where Do We Stand Now | |
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| The Change Process | |
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| Changing Our Destiny | |
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| Clarifying Our Vision and Mission | |
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| Summary | |
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| Developing A Customer-Oriented Organization | |
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| The Customer-Supplier Relationship in Our Society | |
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| Listening to the Voice of Customers | |
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| What Is a Customer-Oriented Organization? | |
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| Understanding the Customer-Supplier Relationship | |
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| Moving from Local Optimization to Total Optimization | |
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| Working on Our Mindset | |
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| Developing the Nervous System in Our Organization | |
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| Clarifying the Flow of Work | |
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| Customer Orientation in a Centrally Planned Economy | |
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| Understanding Customers'' Minds -- Putting Ourselves in Their Shoes | |
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| Criteria for Customer Satisfaction | |
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| Addressing Customers'' Needs | |
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| Developing Customer Orientation Throughout the Company | |
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| Expanding the Concept of the Customer-Supplier Relationship | |
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| Summary | |
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| Establishing A Company Within A Company | |
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| The Customer-Supplier Relationship Between Boss and Subordinates | |
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| The People-Oriented Organization: Making People Before Making Products | |
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| The Mini-Company Concept | |
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| Running Your Own Mini-Company | |
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| The Front Line Supervisor as President of a Mini-Company | |
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| Understanding the Framework of Mini-Companies | |
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| The Meaning of Mission | |
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| Developing a Mission for Mini-Companies | |
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| Benefits of Mini-Companies | |
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| Glass Wall Management | |
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| Even a Stranger Should Understand Our Shop Floor Activities: A Stranger Theory | |
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| Changing Roles and Responsibilities | |
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| Summary | |
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| Involving Everybody In The Process Of Continuous Improvement | |
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| Survival of the Fittest | |
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| Addressing the Organization''s Needs | |
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| Key Points for Organizational Innovation | |
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| Setting up a Scoreboard: Defining the Games We Play | |
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| Diagnostic Tools for Monitoring the Organization''s Health | |
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| Signs of Shop Floor Excellence | |
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| Process of Continuous Improvement | |
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| Improvement and Standardization | |
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| Practicing Standards | |
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| Standards Represent an Organization''s Capabilities | |
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| Use of Standard Operating Procedure to Control the Point of Action | |
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| Developing Standard Operating Procedures | |
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| Maintaining Standards with Everybody Involved: A Wooden Pail Theory | |
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| Guiding Improvement Activity from the Top | |
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| Communicating the Basics of the Mini-Company | |
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| Summary | |
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| Upgrading Everybody''s Skills | |
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| Matching Skills to the Needs of the Organization | |
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| Skills for Self-Management | |
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| Upgrading Our Skills | |
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| Growing with the Organization | |
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| Putting Intelligence on the Shop Floor | |
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| The Role of Managers and Support People | |
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| Working on Important Jobs One Step at a Time | |
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| Instructing People to Conduct the Job -- Job Training | |
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| Encouraging People to Upgrade Their Skills | |
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| Keeping Our Minds Open | |
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| Mental Attitude Toward Continuous Improvement | |
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| A Case of an Operator''s Idea | |
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| Challenging People to Overcome Hurdles | |
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| Summary | |
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| Acquiring Problem-Solving Skills | |
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| Acquiring Willpower for Self-Improvement | |
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| Using Everybody''s Creativity | |
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| Having Fun with "Show and Tell"Necessary Mental Attitudes for Active Problem Solving Identifying Problems | |
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| Tools of Problem Solving | |
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| Learning Skills to Enrich Our Career | |
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| Developing the Habit of Mutual Learning | |
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| Tools to Expose Problems | |
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| Summary | |
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| Practicing Problem-Solving Skills | |
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| Relentless Pursuit of Improvement | |
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| Clarifying Approaches for Problem-Solving Activities | |
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| Basic Steps of Problem Solving | |
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| A Case of Continuous Improvement -- "My Fingers Hurt"Effective Use of Suggestion Programs | |
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| Effective Use of Team Improvement Activities | |
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| Developing a Team-Oriented Environment | |
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| Practicing Problem Solving as a Team | |
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| Intercompany Exchange Program | |
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| Managing the Improvement Process with PDCA | |
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| Summary | |
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| Leading People For Continuous Improvement | |
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| Managers as Leaders: Employees as Customers | |
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| Leadership Is Situational | |
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| A Desire for Self-Improvement Makes Things Happen | |
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| Guiding Improvement Activities | |
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| Having Pride in Our Work | |
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| Sharing Successes | |
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| Improving Communication at the Shop Floor | |
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| Communication with Visual Aids | |
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| Recognition and Rewards | |
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| Letting People Grow with the Company | |
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| Phrases Managers Should Not Use | |
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| Qualification of Leaders | |
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| Providing Positive Reinforcement to Change Our Behavior | |
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| Summary | |
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| Managing Shop Floor Improvement Activities | |
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| Goal Setting | |
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| Benchmarking | |
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| Management Cycle | |
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| Developing the Rhythm of PDCA | |
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| Managing Time on the Shop Floor | |
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| Managing Improvement Activities with Control Points | |
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| Organizing Our Mini-Company Meeting Area | |
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| Organizing Our Work Station | |
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| Learning to Use Control Points | |
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| Developing the Network of Control Points | |
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| Developing Documentation and Presentation Skills | |
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| Reviewing the Progress of Improvement Activities | |
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| Summary | |
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| Tying Shop Floor Management To The Total Company Business | |
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| Company-Wide Planning | |
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| Business Planning for Self-Management | |
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| Developing a Mini-Company Business Plan | |
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| Coordinating the Business Plan Development Process | |
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| Executing the Business Plan | |
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| Sharing the Progress | |
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| Summarizing the Progress in an Annual Report | |
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| Learning from the Business Planning Process | |
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| Tying Business Plan with the Budget | |
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| Policy Management (Management of the Company''s Strategic Direction)Cross-Functional Management | |
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| Coordinating Approaches for Continuous Improvement | |
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| Summary | |
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| Looking At Ourselves In The Mirror | |
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| Tying Things Together | |
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| Evaluating the Level of Shop Floor Management | |
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| The Presidential Audit | |
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| The Audit Process | |
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| Learning from a Presidential Audit | |
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| Learning to Conduct an Effective Presidential Audit | |
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| The External Audit | |
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| Award and Reward Systems | |
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| Finding the Treasures of the Company | |
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| Summary | |
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| Where Do We Go From Here? | |
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| From a Fragile to a Robust System | |
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| Exposing Problems Before It''s Too Late | |
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| Achieving a Critical Mass | |
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| Ideas for Implementation | |
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| Implementing Shop Floor Management Company-Wide | |
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| Making It Work | |
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| The Facilitator''s Role | |
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| Mapping Out the Implementation Process | |
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| Questions and Answers on Implementation | |
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| Shop Floor Management in Perspective | |
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| Benefits of Shop Floor Management | |
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| Where Do We Go from Here? | |
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| Dew and Moon | |
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| Training Our Minds in a Turbulent World | |
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| Summary | |
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| Appendices | |
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| Employee Survey | |
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| Customer Survey | |
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| Checklist for Supervisor''s Roles and Responsibilities | |
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| Developing a Misson Statement | |
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| Checklist for Assuring the Basics of Just-In-Time Production | |
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| Basics of Standard Operating Procedure (SOP) | |
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| Job Training | |
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| Eliminating Human Errors (Poka-Yoke) | |
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| Problem-Solving Tools | |
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| Checklist for Idea Generation | |
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| Advice on Suggestion Program | |
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| Building an Effective Team | |
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| Checklist to Evaluate the Key Steps of Team-Oriented Problem-Solving Activities | |
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| Continuous Improvement Study Group Activities | |
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| Effective Use of Visual Aids | |
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| Supervisor''s Daily, Weekly, Monthly, and Yearly Activities | |
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| Shop Floor Tour Checklist | |
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| Voices of People Who Are Engaged in the New Shop Floor Management | |