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Gemba Walks the Toyota Way : The Place to Teach and Learn Management
Gemba is a Japanese word meaning the actual place where value-creating work happens. Many leaders use gemba only for solving problems, visiting only when there is an issue. Others practice gemba walks on a daily basis to follow up and monitor the situation. However, Toyota believes that leaders truly develop through daily experiences at the gemba. In reality, gemba is a principle for managing, developing and improving people and processes. It is a valuable tool that helps lean practitioners learn the true facts so they can base management decisions on the actual situation.
A Complete Guide to Just-in-Time Production: Inside Toyota's Mind
Yes, people called it an inventory reduction program when they first heard of it. “Just in time” is one of the main pillars in the TPS. “Just in time” ideally means “one-piece flow.” Inventory is the greatest waste in the process, and it hides many problems, such as quality problems, breakdown times, waiting waste, and more. Let’s get back to history. Prior to the 1970 oil crisis, very few people in the world know what Toyota was up to. The fact that it emerged stronger than ever while many of its competitors were quite battered made people take notice. People went to Japan to find out how Toyota had done this. What people found was that Toyota was doing something called “jus...
Hoshin Kanri
Hoshin Kanri has been used successfully by Toyota and other top-tier companies in Japan and the United States to achieve strategic business and lean goals. The underlying power of a successful hoshin kanri process relays on how Toyota creates an environment of continuous improvement. Toyota is a strong business because of its people, and people are the value of its system. This book focuses more on people rather than the process. Management behavior, motivation, core organizational values and teamwork, leadership development, and culture change are the real factors of any business success. Akio Toyoda said after several recent recalls that the rate of the company’s growth was higher than the rate of the development of its people. Successful businesses need to invest in the people and put the people before the process. Read this book and you will see why a gap remains between successful and less successful companies in terms of process management, people management, and the adaptability of culture.
A Failure Mode and Effect Analysis FMEA is a systematic method for identifying and preventing product and process problems before they occur. FMEAs are focused on preventing defects, enhancing safety and increasing customer satisfaction. FMEAs are conducted in the product design or process development stages, although conducting an FMEA on existing products and processes can also yield substantial benefits. Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself.
A Failure Mode and Effect Analysis FMEA is a systematic method for identifying and preventing product and process problems before they occur. FMEAs are focused on preventing defects, enhancing safety and increasing customer satisfaction. FMEAs are conducted in the product design or process development stages, although conducting an FMEA on existing products and processes can also yield substantial benefits. Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself.
Machinery Oil Analysis & Condition Monitoring
Oil analysis is a long-term program that, where relevant, can eventually be more predictive than any of the other technologies. It can take years for a plant's oil program to reach this level of sophistication and effectiveness. This book includes what all practitioners need to know to build an oil analysis program for their machine inspection. This book includes three real case studies and numerous industrial examples to improve machine reliability and enhance the condition monitoring program.
The Seven Deadly Wastes and How to Remove Them from Your Business
This book discusses the seven deadly wastes (muda) in the value stream process. It presents the cost of each waste, its effect on the process, and how it can be eliminated to increase profitability. Waste removal increases the profitability of any business. Processes are classified into value added and waste. The seven deadly wastes that could exist in any manufacturing process originated in Japan and are defined in the Toyota production system (TPS). The main goal became removing them. For each waste, there is a strategy to remove or eliminate it. What is less likely is that managers will know how any of these issues are affecting them and increasing costs. To remove each waste, you have to...
Takt Time: A Guide to the Very Basic Lean Calculation
Takt time is calculated as the amount of manufacturing time that is available divided by the volume of orders. In the 1930s, the German aviation industry employed Takt for the first time as a production management tool. The idea was widely used within Toyota in the 1950s, and by the late 1960s, it had been adopted by the majority of the Toyota supplier base. Every month, Toyota assesses the takt for a process, with a modifying review occurring every 10 days. Takt time is used to properly balance supply and demand. It gives a lean production system its beating heart.
Turning PDCA into a Routine for Learning
Mistakenly, many people think plan-do-check-act (PDCA) is a continuous improvement cycle, even if they neglect the human part. PDCA does aim to improve the process, but if you have only improved the process without developing and teaching your people, you have put the process at risk of slipping back. People must be trained in the culture of continuous improvement so they can keep managing the process with the new method.
Vibration Basics and Machine Reliability Simplified : A Practical Guide to Vibration Analysis
In order to identify unusual vibration occurrences and assess the general health of the test object, vibration analysis is a procedure that tracks vibration levels and looks into the patterns in vibration signals within a component, piece of equipment, or building. It is frequently conducted on both the frequency spectrum, which is derived by applying Fourier Transform to the time waveform, as well as the time waveforms of the vibration signal directly. Mechanical vibration Analysis should present 50% of any condition monitoring program. This book include a practical guide to vibration analysis to prepare practitioners for levels I II & III to become certified analyst. Numerous examples with photos are included to present how to detect different types of equipment and assets failure include: bearing, shafts misalignment, unbalance, rotor problems, electric motors and more using spectrum analysis technique.
Industrial Power Transformers
This book aims to explain the best ways to do work that is usually done to avoid issues with transformers. This book covers everything about choosing and storing transformers. It also talks about advanced methods for checking transformers using predictive maintenance or condition monitoring. It also includes a real example of using FMEA to make power transformers more reliable in a system or production process. The techniques in this book are not for making big changes to repair a transformer. However, many things are done as part of regular procedures. Maintenance and big transformer repair could be the same. We can do the tasks to take care of the transformer if it's not too broken. The advice in this book is similar to the suggestions that companies give for their products. If you need to know how to do something, the person in charge should check the instruction book from the company that made the product. Regularly check and fix small problems to keep transformers in good condition. Also follow special care instructions. Also, if the machine is set up and used the right way, it will keep working for a long time without any issues.
