The book covers basic manufacturing theory and develops a Cartesian approach to explaining lean. It provides a structured fundament how a lean manufacturing system works. Students get a consistent approach, explaining lean by increased complexity (mono-product, multi-product, complex manufacturing systems) with theorems, corollaries, and lemmas. Instructors get explanations for lean based on a systemic model, helping to transmit a clear view about the theory of lean.

This book goes beyond searching for Muda by Gemba walk; the aim is to industrialize the office environment in view of the new digitalization challenge by applying the same principles of Lean industry. Whereas the basic process theory remains valid, the Lean tools have to be adapted and transposed to the office characteristics where not machines but employees are at the center of the transactions. Here, a new, already successfully applied, integrated, industry-derived, and systematic approach is presented. It will not only boost office effectiveness and productivity as well as shortening lead-time of office routines far beyond simple Muda elimination, but it will also prepare the processes in view of the upcoming digitalization era.

This book explains the implementation of just in time (JIT) production in an industrial context, while also highlighting the application of various, vital lean production tools. Shifting the trade-off between productivity and quality, the book discusses the preparation stages needed before implementing a JIT system. After an introduction to lean manufacturing and JIT, it introduces readers to the fundamentals and practice of Kaizen, paying special attention to lean manufacturing tools. The book demonstrates how to use the 5S approach (with the stages of Seiri, Seiton, Seiso, Seiketsu and Shitsuke), Standardized Work, Single Minute Exchange of Die (SMED) and the Kanban system. In brief, the book provides an understanding of the processes associated with the application of these tools and highlights the benefits attained by companies that have implemented JIT systems. Throughout the book, a real-world case study is used to deepen readers’ understanding of how lean manufacturing tools can be implemented. The book is ideally suited for executive courses in industrial engineering and management, but can also be used for upper undergraduate and graduate courses at universities.

Games have been an integral part of Lean Education and Training ever since Hewlett Packard made their 'Stockless Production' video in 1982. Over two decades John Bicheno had been developing and refining games for all aspects of Lean and Operations Management. These have been assembled together to produce a compendium that will be useful to Lean and Operations trainers everywhere. Although one cannot learn about Lean exclusively from playing games, games do allow quick experiential learning that reading about Lean, or listening to a lecture, cannot convey. Games allow players not only to learn about the interaction of particular Lean tools, but also to develop the richness of discussion, participation, and decision making that are essential requirements for successful Lean implementation. This collection covers a wide field including waste reduction, 5S, scheduling, layout, TPM, design, quality, and changeover, as well as an appreciation of the effects of variation and utilization. Some specific and perhaps lesser-known concepts such as Drum Buffer Rope, CONWIP and Bucket Brigade line balancing are also included. All the games presented here have been thoroughly tested and played in plant, academic, and workshop settings.

Interviews with the director of Lawrence of Arabia, Doctor Zhivago, A Passage to India, The Bridge on the River Kwai, and many other epic films

This book is the continuation of the textbook Lean Compendium – Introduction to Modern Manufacturing Theory. It extends the theory of mathematical modeling to batch & queue-based cyber-physical production systems. To facilitate learning, the book continues to develop a Cartesian-derived understanding of the system’s behavior by applying manufacturing-specific theorems, corollaries and lemmas. A law-based description enables to model production mathematically and understand upfront their dynamics in terms of WIP generation, lead-times, exit-rates, and on-time delivery performance. While simulation alone only allows to explore the optimum solution, the development of a theory allows to gain knowledge. This improves the learning of the “physics” of manufacturing systems and contributes to a solid production’s understanding and a clear and cognitive problem determination that leads to a thorough mental capture for mastering a systematic design of such highly complex systems.