Productivity Press 2010-2011 Catalog

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Fundamentals ........................................3

Basics ..................................................3

Classics ................................................6

Shopfloor Series ..................................8

Culture ................................................10

Strategy ..............................................14

Metrics ................................................20

Industries/Functions............................22

Healthcare ........................................22

Office ................................................33

IT ......................................................38

Accounting/Finance ..........................41

Product Development ........................42

Job Shop and Process Management ..43

Supply Chain Management ..............44

Methods & Tools ................................48

Value Stream Management ................48

Problem Solving ................................49

5S ......................................................50

Mistake-Proofing................................52

Quick Changeover ............................54

Cellular Manufacturing ......................56

Kanban ..............................................57

Six Sigma/Statistics ............................58

Total Productive Maintenance............60

Contents



























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Creating a Lean CultureTools to Sustain Lean Conversions, Second EditionDavid Mann

“The new insights included in this second edition of Creating a Lean Culture affirmour examiners recommendations in 2006 to recognize this original work with theResearch and Professional Publication Award."

— Robert D. Miller, Executive Director, The Shingo Prize for Operational Excellence

Now updated to include non-factory environments, the new edition ofDavid Mann’s International Bestseller:

• Shows how to implement Lean management in discrete manufacturing,office, healthcare, and process manufacturing environments

• Shows the difference between measuring improvement through results and through processes

• Includes two versions of the Lean management assessment (available online) one for manufacturingand one for administrative, technical, and professional settings

This crucial work has been translated into Portuguese, Russian, Thai, and Chinese.

Catalog no. K10570, March 2010, 316 pp., Soft Cover, ISBN: 978-1-4398-1141-2, $39.95 / £25.99

Lean Production for Competitive AdvantageA Comprehensive Guide to Lean Methodologies andManagement PracticesJohn NicholasLoyola University Department of Operations, Chicago, Illinois, USA

Based on the author’s three decades of teaching experience, this text introduces theLean philosophy and illustrates the effective application of Lean tools with casestudies from a range of industries. From fundamental concepts to integrated plan-ning and control in pull production and the supply chain, the text provides a com-plete introduction to Lean production. Coverage includes small batch production,setup reduction, preventive maintenance, standard operations, as well as synchro-nizing and scheduling Lean operations. Designed for those with a basic foundationin production and operations management, the text provides a complete understanding of fundamental Leanprinciples.

Catalog no. K11112, July 2010, 527 pp., ISBN: 978-1-4398-2096-4, $79.95 / £48.99

Andy & MeCrisis and Transformation on the Lean Journey, Second EditionPascal Dennis

Praise for the first edition

"… one of the best books I’ve read in a long time on the subject of Lean and theToyota Production System. Don’t be fooled by how simplistic some of the author’ssolutions appear. If properly taught, and then religiously utilized, they will signif-icantly improve your organization. Pascal Dennis is not only a seasoned ‘Sensei’but a good storyteller as well."

— Steve Pontbriand, Senior Vice President, Systems Control

In an era when auto companies are being propped up instead of profiting, many firms are revisiting thisaward-winning fictionalized account and the very real lessons it teaches. The second edition of this enter-taining parable emphasizes practicality and a can do attitude in the face of all challenges, big and small. Thisedition adds study questions that highlight critical leadership lessons and includes corresponding notes thatprovide up-front guidance. The author is a Toyota veteran with two decades of experience as a consultant inLean management and manufacturing.

Catalog no. K11209, November 2010, c. 216 pp., Soft Cover, ISBN: 978-1-4398-2538-9, $29.95 / £18.99

FUNDAMENTALS-BASICS


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Mr. Lean Buys and Transforms a ManufacturingCompanyThe True Story of Profitably Growing an Organization withLean PrinciplesGreg Lane

"…. Assuming you subscribe to management being synonymous with improve-ment, you are sure to come away from this book with a clear plan for a few newimprovements."

— Xavier Pujol, Plant and Site Manager, Continental Corporation

This is the true story of how, armed with only Lean improvement methodologies, aspecially trained Toyota Lean expert purchased a business he knew nothing about,applied Lean techniques, and succeeded in doubling sales and increasing profitability. With humility andhumor, the author recounts his successes and failures, introduces his key employees and their struggles withchange, and provides motivation and simple ideas for all readers looking to improve their businesses.

Catalog no. K10777, January 2010, 296 pp., ISBN: 978-1-4398-1516-8, $39.95 / £25.99

Working with MachinesThe Nuts and Bolts of Lean Operations with JidokaMichel Baudin

"… very informative … easy to read … it will help many readers understand howto incorporate the roles of machines into modern-day management."

— Imai Masakki, Founder, Kaizen Institute

Exploring the modern role of machines, this book explains how performance dif-ferences factory to factory can be directly linked to how people use machines. Itcovers human interfaces for individual machines, management of monuments andcommon services, automation, maintenance, and production control. It providesstrategies and tools for making technical and managerial decisions about machinesthat will improve efficiency and profitability. The author emphasizes the importance of the jidoka pillar of theToyota Production System and discusses ways to group machines together into cells.

Catalog no. PP7329, 2007, 368 pp., ISBN: 978-1-56327-329-2, $59.95 / £38.99

Toyota Kaizen MethodsSix Steps to ImprovementIsao Kato and Art Smalley

This workbook is the first of its kind to document and outline the actual kaizen prac-tices taught within the Toyota Motor Corporation to develop leadership skills andpersonal responsibility close to the manufacturing floor. By explaining in full con-text the six basic kaizen principles that govern Toyota, the authors enable readersto improve their own skills and those of their employees making full use of thekaizen approach. The text examines simple analytic methods for work elements,time, motion, production lead-time, machine losses, and standardized work.

Catalog no. K11748, October 2010, c. 151 pp., Soft Cover, ISBN: 978-1-4398-3853-2, $49.95 / £31.99

FUNDAMENTALS-BASICS






Lean Production SimplifiedSecond EditionA Plain-Language Guide to the World's Most PowerfulProduction SystemPascal Dennis

"Lean Production Simplified is both enlightening and informative for all levels ofLean learners. It is written from a very human perspective.

— Anne Stevens, VP, North America Vehicle Operations, Ford Motor Company

A Shingo Prize Winner for Excellence in Manufacturing Research, this book deliversan inside practitioner’s view of Lean manufacturing. It looks at the origins andunderlying principles of Lean, discusses practical problem solving for Lean produc-tion, and details activities that support involvement, including kaizen circles and suggestion systems. It cov-ers the Lean Improvement Process; Production Physics and Little's Law; Value Stream Thinking; the HoshinPlanning and Execution Tree diagram, and Problem Solving by way of the Five Why method.

Catalog no. PP7356, 2007, 192 pp., Soft Cover, ISBN: 978-1-56327-356-8, $39.95 / £24.99

Insights on ImplementationA series of books as inspirational as they are informativeInsights on Implementation, a book series from Productivity Press, bringstogether a variety of case studies around specific topics important to those organi-zations thinking about or in the process of implementing lean improvements orthose thinking about taking their lean improvements to the next level. It giveshands-on executives and managers the opportunity to learn from the direct expe-riences of others in the same position. While each book provides a number of inspir-ing examples, the collections also include attempts that came up short of the mark,as it is better to learn from others’ missteps rather than from your own. • Writtenin a conversational, easy-to-read style

• Provides practical, in-depth descriptions of typical lean concerns

• Shows you methods used to engage all the stakeholders in an organization

• Affordably priced to share with all key personnel in your organizations

Lean Supply Chain: Collected Practices and Cases


The Lean Office: Collected Practices and Cases


Lean Culture: Collected Practices and Cases


Visual Tools: Collected Practices and Cases


TPM: Collected Practices and Cases


Improving Flow: Collected Practices and Cases


FUNDAMENTALS-BASICS










JIT Implementation ManualThe Complete Guide to Just-in-Time Manufacturing, Second Edition (6-Volume Set)Hiroyuki Hirano

Known as the JIT Bible in Japan, this six-volume set presents the genius of HiroyukiHirano who leaves no detail to chance in explaining how to implement and main-tain a Just-in-Time manufacturing program. Encyclopedic in scope, this new re—released edition provides information on every aspect of JIT, from its philosophicalunderpinnings to the myriad systems, techniques, and tools for every factory set-ting. While each volume is available individually, we have affordably priced the setto honor Hirano’s recommendation that readers "avoid taking a piecemealapproach… The overall flow is the most important aspect of production, and the keyingredient for creating a good overall flow is comprehensive improvement… ."

Volume 1 — The Just-In-Time Production SystemVolume 2 — Waste and the 5S’sVolume 3 — Flow Manufacturing – Multi-Process Operations and KanbanVolume 4 — Leveling – Changeover and Quality AssuranceVolume 5 — Standardized Operations – Jidoka and Maintenance/SafetyVolume 6 — JIT Implementation Forms and Charts


A Study of the Toyota Production SystemFrom an Industrial Engineering ViewpointShigeo Shingo and Andrew P. Dillon

The green book that started it all, this is first book on JIT in English written from theengineer's viewpoint. When Omark Industries bought 500 copies and studied itcompany-wide, Omark became the US pioneer in JIT. It provides Dr. Shingo's clas-sic industrial engineering rationale for implementing process-based rather thanoperational improvements in manufacturing. He explains the basic mechanisms ofthe Toyota Production System, examines production as a functional network ofprocesses and operations, and then discusses the organization-wide mechanismnecessary to make JIT possible in any manufacturing plant. He demonstrates newways to think about profit, inventory, waste, and productivity.


Inside the Mind of ToyotaManagement Principles for Enduring GrowthSatoshi Hino

“For anyone interested in understanding Toyota's functions and capabilities as atotal system, this book is a must read."

— Professor Fujimoto Takahiro, University of Tokyo

"The most thorough explanation of the unique learning culture that Toyota hasbuilt, which is the real key to their phenomenal business success"

— George Koenigsaecker, Simpler Consulting Inc.

Winner of a Shingo Prize for Excellence in Manufacturing Research, this book pres-ents a fresh and detailed analysis of Toyota’s essential management system, wherethe goal is not simply to mimic Toyota’s formula, but to learn from it and, in doing so, surpass it.


FUNDAMENTALS – CLASSICS






Non-Stock ProductionThe Shingo System of Continuous ImprovementShigeo Shingo

Shingo, whose work at Toyota led to Just in Time Manufacturing, teaches how toimplement non-stock production in JIT operations. The culmination of his extensivewritings on production and improvement, this book provides a companion to hisother landmark books on key elements of JIT, including SMED and poka-yoke. Hecovers basic concepts for improving production, and in examining various produc-tion systems, exposes fundamental flaws in European and American productionphilosophies. He also delves into the scientific thinking mechanism -- a newapproach to improvement, and discusses production functions in both authorizedstock and non-stock production environments.


Today and TomorrowCommemorative Edition of Ford's 1926 ClassicHenry Ford

"Today and Tomorrow is timeless. Within its pages, we find Henry Ford's philoso-phy of Lean manufacturing -- the roots of today's Ford Production System."

—James J. Padilla, Group Vice President, Ford North America

Henry Ford is the man who doubled wages, cut the price of a car in half, and pro-duced over 2 million units a year. Time has not diminished the progressiveness ofhis business philosophy, or his profound influence on worldwide industry. The mod-ern printing of Today and Tomorrow features an introduction by James J. Padilla,Group Vice President, Ford North America. It also includes an enhanced selectionof photos illustrating the processes and facilities Ford covers in the text. Taiichi Ohno acknowledged that akey stimulus to JIT was his close reading of this book. Today, these same ideas are re-emerging to revitalizeAmerican industry in new ways.


Toyota Production SystemBeyond Large-Scale ProductionTaiichi Ohno

In this classic text, Taiichi Ohno -- inventor of the Toyota Production System andLean manufacturing -- shares the genius that sets him apart as one of the most dis-ciplined and creative thinkers of our time. Combining his candid insights with a rig-orous analysis of Toyota's attempts at Lean production, Ohno explains how Leanprinciples can improve any production-oriented endeavor. A historical and philo-sophical description of just-in-time and Lean manufacturing, this work is a mustread for all students of human progress. On a more practical level, it continues toprovide inspiration and instruction for those seeking to improve efficiency throughthe relentless elimination of waste.


FUNDAMENTALS – CLASSICS






Train Your Workforce with Our Shopfloor Series

Autonomous Maintenance forOperatorsIntroduces operators to equipment maintenance andmotivates them to take ownership of their equipment.

ISBN: 978-1-56327-082-6 $28.95 US £17.99 UK

Cellular ManufacturingIntroduces production teams to cellular manufactur-ing concepts and prepares them to help in thedesign of new cells.

ISBN: 978-1-56327-213-4 $28.95 US £17.99 UK

Just-in-Time for OperatorsShares lean manufacturing principles of waste reduc-tion, inventory control, cell layout, & support tech-niques.

ISBN: 978-1-56327-133-5 $28.95 US £17.99 UK

TPM Team GuideEmphasizes integration of TPM with productionmanagement. Perfect for supervisors, operators, facil-itators, and trainers.

ISBN: 978-1-56327-079-6 $28.95 US £17.99 UK

Pull Production for theShopfloorGain knowledge that can be used to understand,plan, and implement pull production.

ISBN: 978-1-56327-274-5 $28.95 US £17.99 UK

Standard Work for theShopfloorEstablishes the best activities and sequence steps tomaximize performance and minimize waste.

ISBN: 978-1-56327-273-8 $28.95 US £17.99 UK

Kaizen for the ShopfloorTakes you through the steps in conducting an effec-tive kaizen event.

ISBN: 978-1-56327-272-1 $28.95 US £17.99 UK

Identifying Waste on theShopfloorAn excellent guide to understand, identify, and elim-inate waste on the Shopfloor.

ISBN: 978-1-56327-287-5 $28.95 US £17.99 UK

FUNDAMENTALS – SHOPFLOOR SERIES



















Kanban for the ShopfloorProvides the information needed to understand,plan, and implement kanban.

ISBN: 978-1-56327-269-1 $28.95 US £17.99 UK

Quick Changeover forOperatorsFeatures Shingo’s SMED approach for shorteningsetups and boosting manufacturing flexibility.

ISBN: 978-1-56327-125-0 $28.95 US £17.99 UK

Mistake-Proofing forOperatorsIntroduces poka-yoke methods for preventingdefects by monitoring process conditions at thesource.

ISBN: 978-1-56327-127-4 $28.95 US £17.99 UK

TPM for SupervisorsGives supervisors a practical and to-the -point under-standing of the benefits of TPM and their role in mak-ing it successful.

ISBN: 978-1-56327-161-8 $28.95 US £17.99 UK

TPM for Every OperatorFocuses on basic TPM principles, autonomous main-tenance, and safety.

ISBN: 978-1-56327-080-2 $28.95 US £17.99 UK

OEE For OperatorsMakes overall equipment effectiveness accessible toworkers who have the most to gain from improvingequipment.

ISBN: 978-1-56327-221-9 $28.95 US £17.99 UK

Focused EquipmentImprovementGives your TPM teams a powerful framework for fur-ther improving equipment performance.

ISBN: 978-1-56327-081-9 $28.95 US £17.99 UK

5S for OperatorsThis book will teach your workers the basics of: Sort,Set in Order, Shine, Standardize, and Sustain. Filledwith illustrations, page headers, chapter summaries,and application questions, it proves that learning canbe fun.

ISBN: 978-1-56327-123-6 $28.95 US £17.99 UK

FUNDAMENTALS – SHOPFLOOR SERIES

The Productivity Press Development Team:Recipients of the Shingo Prize!



















Staying LeanThriving, Not Just SurvivingPeter Hines, Pauline Found, Gary Griffiths, and Richard Harrison

Originally self-published, this report was awarded a 2009 Shingo Prize. It draws onthe experience of a real multi-national multi-site company that has successfullyimplemented Lean in its manufacturing and commercial sectors with great results.In presenting a model of sustainable change, the text addresses the elements ofsuccessful Lean management that are often difficult to emulate as well as the morevisible features of process management. Stressing a rigorous approach, this casestudy covers a complete six-year Lean transformation involving the application ofthree distinct roadmaps.

Catalog no. K11258, January 2011, c. 128 pp., Soft Cover, ISBN: 978-1-4398-2617-1, $39.95 / £25.99

A Culture of Rapid ImprovementCreating and Sustaining an Engaged WorkforceRaymond C. Floyd

“Ray Floyd describes what a high contribution, autonomous action organizationis and why you want and need one.”

— David Roberts, Director Product Development (retired), The Proctor & GambleCompany

Filled with lessons garnered from practical experience, this text is based on RayFloyd's 40 years of industrial management, including his more than 20 years atExxon Mobil. He is a Shingo Prize winner and also holds the unique distinction ofhaving led businesses from two different industries that were both recognized byIndustryWeek as being among the Best Plants in America. The work identifies and demonstrates the applica-tion of the management tasks required to inspire and develop a culture of improvement that actively involvesall stakeholders. If you approach the task of improvement with full participation, improvement is not just pos-sible, but inevitable.


What Works for GE May Not Work for YouUsing Human Systems Dynamics to Build a Culture of ProcessImprovementLawrence Solow and Brenda Fake

"Want to increase your success rate on process improvement? Read this book andincorporate its ideas into your approach."

—Warren Wilhelm, President, Global Consulting Alliance

"This book will make your Lean Six Sigma efforts stick."—John V. Grice, Industrial Statistician, Six Sigma Master Black Belt

Focusing on Lean, Six Sigma, and Human Systems Dynamics, this guide providesnew tools for managing and sustaining process improvement in today’s complexnon-linear environments. With more than 50 combined years of change management and process improve-ment consulting experience, the authors offer valuable practical insights for creating dynamic organizationalchange.

Catalog no. K11248, May 2010, 206 pp., ISBN: 978-1-4398-2599-0, $39.95 / £25.99

CULTURE






Implementing TWICreating and Managing a Skills-Based CulturePatrick Graupp and Robert J. Wrona

Featuring modernized implementation strategies employed in Lean initiativestoday, this volume describes the experiences of a variety of companies using TWI,more than 60 years after Training within Industry turned the U.S. into the industri-al giant that won World War II. Based on their experience implementing TWI incompanies across the world, Graupp and Wrona, highlight critical elements andpoint out key stumbling blocks to a successful TWI implementation. Designed as ahands-on manual, the book includes case studies as well as a variety of updatedtools and templates.

Catalog no. K11246, November 2010, c. 498 pp., ISBN: 978-1-4398-2596-9, $49.95 / £31.99

Training Within IndustryThe Foundation of LeanDonald Dinero

"This excellent historical overview … will educate decision makers on what the JobInstruction, Job Methods and Job Relations programs are, how each is delivered,and the significant impact each TWI program can have on their organization."

— Robert J. Wrona

Winner of a Shingo Prize for Excellence in Manufacturing Research, this book eluci-dates the history and application of the four modules that comprise TWI. Theauthor explores a crucial piece of a Lean initiative that is often overlooked. Hedemonstrates how to train employees to perform tasks quickly with minimal waste,improve processes using existing resources, solve personnel problems in an analytical manner that allowsemployees to stay focused, and develop robust training plans to meet the particular needs of a specific plant.

Includes a generic TWI organizational chart, and a CD with early TWI training materials.


The TWI WorkbookEssential Skills for SupervisorsPatrick Graupp and Robert J. Wrona

Winner of a Shingo Prize for Excellence in Manufacturing Research, this criticallyacclaimed text continues to reintroduce the U.S. to TWI. It demonstrates efficientways to instruct employees on how to perform jobs safely and conscientiously;looks at ways to produce more quality products in less time through the handlingof workforce, machines, and materials; and shows how to improve performancewith employee relations that preemptively prevent problems. The authors includeexercises that can be applied to readers’ own worksites. A companion CD providesforms needed to complete the exercises and implementation case studies.


CULTURE






Lean SafetyTransforming your Safety Culture with Lean Management Robert Hafey

"If the strength of your company is dependent on developing an exceptional work-force, then start where it matters most – providing the tools for a safe, efficientand involved employee group. This book can be the roadmap to get you there."

— Jerry Paulson, former President and CEO, Flexco

Written by a leader in Lean implementation with more than 30 years of experience,this book provides the knowledge necessary to both assess and improve safety pro-grams through use of Lean tools and techniques. The text focuses on culturalchange, leadership, improvement methodologies, investigations designed to get atroot causes, and the metrics required to track and maintain a fluid approach to safety. The author takes les-sons learned from Lean and applies them to the building of a world-class safety-first organization.

Catalog no. K10844, January 2010, 186 pp., Soft Cover, ISBN: 978-1-4398-1642-4, $39.95 / £25.99

Learning OrganizationsDeveloping Cultures for Tomorrow's WorkplaceJohn Renesch and Sarita Chawla

"In a rich dialogue of many voices, this book explores some key ideas of an emerg-ing new management paradigm. Community, networks, feedback, self-organiza-tion, and learning are essential aspects of understanding business organizationsas living systems. For managers and entrepreneurs in the twenty-first century thisperspective will be vital."

— Fritjof Capra, Author, The Turning Point

Bringing together 32 essays written by 39 highly respected organizational leadersand scholars, this volume provides a wide range of perspectives on how workplacecultures both cultivate and inhibit organizational learning and development. Lead authors include Harvard'sRosabeth Moss Kanter, London Business School's Charles Handy, and MlT's Fred Kofman and Peter Senge. Theessays in this collection are organized in four sections: Guiding Ideas, Theories/Methods/Processes,Infrastructure, and Arenas of Practice.


Developing a Lean WorkforceA Guide for Human Resources, Plant Managers, and LeanCoordinatorsChris Harris and Rick Harris

"… required reading for Human Resource Managers in organizations implement-ing Lean systems."

— David Saylor, Managing Director of Manufacturing, Masco Builder Cabinet Group

With an HR perspective, veteran consultants Chris Harris and Rick Harris walk read-ers through a simple, step-by-step proven method for transforming a mass pro-duction workforce into a Lean thinking one that possesses the necessary skills, train-ing, and attitude to march in a new direction. They explain the role of humanresources in a Lean-oriented facility, emphasizing systematic ongoing training for all employees. They also dis-cuss the value of promoting employees from within and the importance of flexibility. This critically acclaimedbook includes sample training sessions with explanations.


CULTURE






Stories from My SenseiTwo Decades of Lessons Learned Implementing Toyota-StyleSystemsSteve Hoeft

"Steve is a real sensei. His presentations captivate students. His enthusiasm is con-tagious. When Steve writes about the TPS house it is not just an abstraction. It issomething he lives."

— Jeffrey K. Liker, author of The Toyota Way

In this unique volume, the author, a Toyota-trained expert, employs memorablestories from his own learning experiences to teach Toyota Production System prin-ciples. Organized according to the Toyota House model of Lean, the stories providea framework for understanding. Each story is complemented by questions that encourage the reader to reflecton how each principle applies in their own business, process, or life. Each chapter includes a more detaileddescription of the tools and principles in the respective part of the house model.


Sustaining LeanCase Studies in Transforming CultureEdited by

Association for Manufacturing Excellence

Maybe the greatest challenge facing those implementing Lean is how to sustainmomentum. While implementation tools are critical, the most essential tool thatmanagers require is confidence. One way to gain that confidence is to hear the sto-ries of others who have survived the same challenges. This volume, the third com-pilation of articles published in AME’s well-regarded Target magazine, answers thatneed. While a few of the articles broadly discuss transformation, the vast majoritypresent highly illuminating and often inspirational case studies that show how well-known companies have successfully transformed lackluster cultures into ones where prosperity thrives.


Feedback Toolkit16 Tools for Better Communication in the WorkplaceRick Maurer

"This clearly written book is like having your own personal coach assisting youwith techniques that foster productive interactions. … especially useful for man-agers and employees in organizations that do not have internal human resourcesdevelopment staff."

— Nedra Weinstein, Manager, Human Resource Development, PBS

Used well, feedback can motivate people to their highest level of performance. RickMaurer's Feedback Toolkit provides managers with a very accessible and well-organized guide for creating and maintaining open and productive communicationin the workplace. Detailing a systematic approach to enhancing communication throughout an organization,it provides 16 practical and creative approaches for giving and receiving feedback. It covers how to maximizefeedback from your boss, from peers, and from a coach, as well as feedback from questionnaires.

A new edition of the Feedback Toolkit will be available in January 2011 – ISBN: 978-1-4398-4093-1


CULTURE






Critical Success Factors SimplifiedImplementing the Powerful Drivers of Dramatic BusinessImprovementMarvin T. Howell

"If you want to be a senior executive or project leader, or if you are a senior exec-utive or project leader and want to keep your job, read this book and put its prin-ciples to work."—Joseph A. "Bud" Ahearn, Major General, US Air Force (retired), Vice Chairman, emeritus,

CH2MHill, Ltd

This book simplifies the identification, measurement, and use of CSFs to successful-ly implement strategies, manage projects, and improve processes. It provides meas-urement techniques for tracking progress, highlighting problem areas, and facilitating improvements. The firstpart covers the background of CSFs, including Rockart's CSF Method, along with two techniques for identi-fying external CSFs, and a simple process to generate internal CSFs. The second part addresses specific appli-cations of CSFs, from strategic planning to individual pursuits.


Escape the Improvement TrapFive Ingredients Missing in Most Improvement RecipesMichael Bremer and Brian McKibben

“We have all suffered from the difficulty of sustaining improvement, and this booklays the sustaining process in a simple common sense way that is easy to read.”

— Basem Hishmeh, Chairman, Sigma-Netics, Inc.

Despite performance improvement initiatives such as Lean, Six Sigma, and Supply-Chain Management, only a handful of companies actually break out of the pack totransform their enterprise. Providing helpful methods and metrics for effecting truechange, this book demonstrates how to avoid common improvement traps thatinhibit many organizations from rising above the rest.

Catalog no. K10932, September 2010, 319 pp., Soft Cover, ISBN: 978-1-4398-1796-4, $49.95 / £31.99

From Belief to KnowledgeAchieving and Sustaining an Adaptive Culture in OrganizationsNeil Douglas and Terry Wykowski

“…well written, thoughtful and thought provoking … offers leaders and scholarsof change a considered opportunity to explore the transitions along the continu-um from belief to knowledge that can lead to sustainable change.”

— Sue Dopson, Said Business School, University of Oxford

Rather than offer simple recipes, this book shows how good leaders can evolve andsustain an adaptive culture that develops knowledge through purposeful humaninteraction. It explores key dynamics of learning, considers the diversity of beliefspresent in any group, and demonstrates ways to explore and encourage the poten-tial of both the group and individuals within the group. It demonstrates the importance of unearthing beliefsto find the roots and persistent influences that preserve them. It gives us a much broader definition of orga-nizational knowledge than that associated with IT and the currently popular idea of knowledge as an asset.

Catalog no. K11694, August 2010, 261 pp., ISBN: 978-1-4398-3734-4, $59.95 / £38.99

STRATEGY






Leading the Lean Enterprise TransformationGeorge Koenigsaecker

"Any senior executive serious about leading a Lean transformation should starthere.”

— Larry Culp, president and CEO, Danaher Corporation

"This truly worked for us, and continues to make our Air Force better. The messagecomes with great stories and legendary examples to make Leading the LeanEnterprise Transformation readable for all."

— Michael W. Wynne, 21st Secretary, United States Air Force

Written to help executives determine right from wrong during a Lean initiative, thislively work shows that Lean is more about an approach than it is about tools. It pres-ents the successful strategies and case histories of several key American leaders who have been instrumentalin bringing Lean to the forefront of various industries.


Quality ManagementTheory and ApplicationPeter D. Mauch

Quality is not an engineering discipline, but a business practice. Peter Mauch offershis expertise in this groundbreaking book, demonstrating the necessity of consid-ering quality as a sustained management activity. Divided into five sections, thebook covers staffing, motivation, control, planning, and organization. It offers qual-ity management practices and discusses the impact of managing for qualitythroughout an organization. The book addresses the alignment of individualdepartments to maximize quality, business planning and success metrics, recordkeeping, and department level quality control implementation.


Simple ExcellenceOrganizing and Aligning the Management Team in a LeanTransformationAdam Zak and Bill Waddell

This book explains the critical role that each member of the senior managementteam must play in achieving a company’s transformation to a Lean organization. Itcharts a course of simplification, in contrast to the complications that pervade tra-ditional management by functional silos, and also the increasing complexity ofmanaging popular improvement initiatives such as Lean, Six Sigma, and Theory ofConstraints. Written by well-known authorities, the book includes case studies fromcompanies recognized for excellence. This is the first book to spell out in detail therole of each key individual on the management team, including sales and market-ing, human resources, purchasing/supply chain, information technology, finance, and engineering.


STRATEGY






It's About TimeThe Competitive Advantage of Quick Response ManufacturingRajan Suri

Presenting the developments in QRM since the publication of Rajan Suri’s landmarktext, Quick Response Manufacturing, this book illustrates how QRM can not onlyreduce lead times but also improve quality, reduce operating costs, and enablecompanies to gain a substantial market share. It explains how factories in advancednations can use QRM strategy to compete with manufacturers in low-wage coun-tries and provides helpful pointers for QRM implementation, including accountingstrategies, novel cost-justification approaches, and a stepwise process for imple-mentation. It also includes a CD with time-saving tips to help you work throughimplementation issues—including simple calculation methods and tools to supportthe design of your QRM strategy.

Catalog no. K10299, March 2010, 228 pp., ISBN: 978-1-4398-0595-4, $39.95 / £25.99

Listening to the Voice of the MarketHow to Increase Market Share and Satisfy Current CustomersR. Eric Reidenbach

Unique in its approach, this book focuses on the voice of the market (VOM) insteadof the much more limiting voice of the customer (VOC). While the VOC typicallyrefers to what the organization’s customers say, feel, or need, the voice of the mar-ket focuses not only on the needs of its customers, but also on those belonging tocustomers across other organizations in addition to one’s own. By focusing on theVOM, organizations can empower Six Sigma and Lean initiatives with a source ofinformation that expands one’s view of the marketplace, which can be self-fulfillingin its limitation.

Catalog no. PP9330, January 2010, 205 pp., ISBN: 978-1-4200-9330-8, $54.95 / £34.99

FlexibilityFlexible Companies for the Uncertain WorldGill Eapen

“For your company or your career, Flexibility is a worthwhile guide to problemsolving and decisiveness amid the uncertainty.

— Martin Mackay, President, PharmaTherapeutics Research and Development

In an information and knowledge-driven environment with high levels of uncer-tainty, most traditional ideas of structure, system, and strategy are ineffective. Thisbook shows how to create, maintain, and accelerate an organization in a highlyuncertain environment using flexibility. It analyzes the organization holistically anddetails its primary components independently. The author presents an economicframework of decision options to diagnose existing flexibility problems and provides guidance on how toimprove flexibility and reduce risk.


STRATEGY






CompressionMeeting the Challenges of Sustainability Through VigorousLearning EnterprisesRobert W. Hall

"Strategic leaders should not labor under the misconception that they will learnby reading this book. It is through using what they read that the real and impor-tant learning will occur."

— John (Jack) Ward, former CEO, Gabor International

"Learning how to survive in this new Era of Sustainability will require a new wayof thinking and working ... .”— Glenn Marshall, Northrop Grumman Shipbuilding, Benchmarking & Sustainability Champion

Global crises are squeezing us from all directions and with or without our participation, change will occur. Toimplement the sort of changes that will allow civilization to prevail rather than merely endure requires aresourcefulness and ingenuity beyond any the world has ever employed. In this volume, Doc Hall shows ushow to learn to learn more effectively both as individuals and organizations, and in terms of processes. Heinvites us to rethink our perpetual devotion to old ideals and welcome the shift in thinking that must be ourfirst and immediate step. Visit the compression website at compression.org


Understanding A3 ThinkingA Critical Component of Toyota's PDCA Management SystemDurward K. Sobek II and Art Smalley

The A3 report has proven to be a key tool In Toyota’s successful move toward orga-nizational efficiency. The power of the A3 report, however, derives not from thereport itself, but rather from the development of the dynamic culture required forthe implementation of an A3 system. Winner of a 2009 Shingo Research andProfessional Publication Prize, this manual highlights the deep learning and profes-sional development that occurs through the A3 process. The authors show that thereport is an especially effective tool when implemented in conjunction with aPDCA-based management philosophy. The book includes some very practicaladvice on how to write and review A3 reports.


Green IntentionsCreating a Green Value Stream to Compete and WinBrett Wills

Developed by a plant manager who experienced the challenges to going green,Green Intentions shows how the green value stream provides a dynamicapproach to making green improvements. It defines each of the seven greenwastes, explains the overall green value stream process, demonstrates how to mapyour green value stream, and provides guidance on implementation. Its practicalapproach shows how to realize initial savings from green initiatives so as to gain thesupport and momentum needed to eliminate all green wastes, leading to environ-mental sustainability as well as substantial business benefits, including new cus-tomers, improved employee retention, and increased revenues.

Catalog no. PP9617, January 2010, 296 pp., Soft Cover, ISBN: 978-1-4200-8961-5, $39.95 / £25.99

STRATEGY






The Ultimate Improvement CycleMaximizing Profits through the Integration of Lean, SixSigma, and the Theory of ConstraintsBob Sproull

This text uniquely integrates Lean concepts, Six Sigma, and the Theory ofConstraints into a combined business strategy aptly named the UltimateImprovement Cycle (UIC). Unlike other systems, the UIC is all about economizingresources by focusing improvement efforts on those key leverage points that willprove most optimal, rather than diluting one’s efforts with an expensive across-theboard-approach to improvement. The UIC is derived from Bob Sproull’s years ofexecutive experience with the Toyota Production System and consulting work withseveral high profile companies. He shows you how to take advantage of the cycli-cal nature of improvement to implement change that is perpetually effective and requires no more resourcesthan you have on hand.


Hoshin Kanri for the Lean EnterpriseDeveloping Competitive Capabilities and Managing ProfitThomas L. Jackson

"Tom Jackson's practical and valuable insights are rivaled only by the importanceand benefits of applying Hoshin Kanri."

— Jamie Flinchbaugh, co-author, The Hitchhiker's Guide to Lean

Winner of a Shingo Prize For Excellence In Manufacturing Research, this book facili-tates an understanding of hoshin kanri as a grand design implemented through asystem of team agreements. It defines an improved X-matrix that incorporates ascorecard for identifying improvement opportunities and converting them into bot-tom line results in terms that financial managers can support. Beyond theory, itdemonstrates the mechanics of hoshin kanri to accelerate brand equity while initiating Lean manufacturingand Six Sigma improvements. Accompanying the text is a CD containing forms, meeting agendas, and exam-ples of X-matrices that are applicable to marketing, design engineering, and manufacturing.


Using Hoshin Kanri to Improve the ValueStreamElizabeth A. Cudney

"… provides a clear and concise view of how to best use hoshin kanri to driveimprovement and realize the level of results organizations want and need. Thisbook should be required reading for all business executives."

— Karen Martin, author of The Kaizen Event Planner

While value stream mapping is now accepted as a tool for identifying waste, futurestate mapping presents greater challenges. Achieving the full implementation pic-tured in an enhanced future state map is far more complex than its development.Hoshin kanri can help. This method encourages employees to incorporate per-formance metrics to reach the root cause of problems before searching for solutions and teaches them howto promote the achievement of sustainable implementation. Though developed in Japan this technique isbased on Deming’s classic PDCA (Plan-Do-Check-Act) improvement cycle. A number of Deming Prize winnerscredit hoshin kanri as being key to their business success.


STRATEGY






The Toyota Kaizen ContinuumA Practical Guide to Implementing LeanJohn Stewart

Written by an expert, who in his 18 years with Toyota moved from an entry level operational position to theexecutive ranks, this very practical book provides a firsthand account on how to implement the ToyotaProduction System (TPS) throughout an organization. It answers questions on how to get the process startedand how to get senior management excited about embracing TPS. The author, who has overseen imple-mentations in various environments and cultures, gives real knowledge supported with examples so as toequip readers with the ability to make immediate improvements in their areas of responsibility.

Catalog no. K12059, February 2011, c. 180 pp., Soft Cover, ISBN: 978-1-4398-4604-9, $39.95 / £25.99

20 Keys to Workplace ImprovementIwao Kobayashi

"This is the first work I have read that sets a structure and framework for organi-zations to follow if they wish to revolutionize the workplace. Kobayashi hasremoved the mystery of how to accomplish major improvement in a business. Hisinsight is true genius!"

— John Sutter, VP of Manufacturing, National Rubber Company, Inc.

Kobayashi is considered a genius by those who have adopted his reorganizationstrategies. Through this volume, he has helped many manufacturing companiesintegrate several of the best improvement methods into a coordinated system fordrastic and continual improvement that will lead to enhanced quality and produc-tivity and fewer errors. This program provides the strategies necessary to achieve ambitious goals through afive-level scoring system. It provides criteria for the five-levels that will guide your company to world-class sta-tus. Two valuable case studies demonstrate effective use by both a Japanese company and an American man-ufacturer.


Progressive KaizenThe Key to Gaining a Global Competitive AdvantageJohn W. Davis

Designed to teach the reader how to fully maximize kaizen events, this bookdescribes the four distinct types of kaizen and the specific purpose of each. It thendemonstrates how kaizen can be used as a prominent strategy when implement-ing Lean. This includes developing a structured plan for kaizen and giving strongconsideration for using employee incentives to motivate improvements at the indi-vidual job level.

• Provides a detailed description of the various types of kaizen and how andwhen to use them in order to obtain the greatest return on the investment ofcritical resources

• Outlines how to conduct each type of kaizen event, who should be involved as participants, and whatthe expected results should be

• Explains how to incorporate a unique Waste Reduction Activity Process (WRAP) that drives kaizen downto the individual job level and encourages on-going participation

• Teaches how to expand both the use and effectiveness of kaizen processes


STRATEGY






The Basics of Performance MeasurementSecond EditionJerry L. Harbour

While every smart executive now knows that you can’t understand, manage, orimprove what you don’t measure, it was Jerry Harbour who turned that adage intothe science of performance measurement. Harbour provides a six-step method fordeveloping a performance measurement system. He shows how to design per-formance measurement families and how to build hierarchies tailored to differentlevels within an organization. He also covers collection and distribution, as well asthe value of performance measure displays. When you finish this book, you will beable to undertake performance measurement with new confidence. You will alsocome away knowing how to present your findings with an authority that will con-vince stakeholders of the importance and accuracy of your results.

Catalog no. K10132, 2009, 102 pp., Soft Cover, ISBN: 978-1-4398-0249-6, $14.95 / £9.99

Applied Concept MappingTheory, Techniques, and Case Studies in the BusinessApplications of Novakian Concept MappingEdited by

Brian Moon, Robert R. Hoffman, Joseph Novak, and Alberto Canas

Providing case studies in business applications, this book describes the theory andmethods underlying Novakian concept mapping. Developed by Joseph Novak asan educational strategy, concept mapping has been applied with increasing fre-quency to problems in the workplace. Novakian concept maps differ from otherdiagrams by their morphology, content, and semantics. The advent of Cmap Tools,a knowledge modeling software kit that enables computer-based creation and shar-ing of Novakian concept maps, has encouraged a wide range of mapping applications. The text presents orig-inal work from the authors and other contributors who have applied concept mapping in various businessenvironments, including consumer products, engineering/product development, defense, and healthcare.

Catalog no. K11403, December 2010, c. 288 pp., ISBN: 978-1-4398-2860-1, $59.95 / £38.99

The Performance ParadoxUnderstanding the Real Drivers that Critically Affect OutcomesJerry L. Harbour

A complement to Harbour’s, The Basics of Performance Measurement, this workempowers managers to establish protocols that will measure and improve the per-formance of their employees and ultimately, their businesses. Harbour begins witha conceptual overview of performance as a whole. He then explores practical impli-cations, covering modeling, measuring, and improved performance. Augmentedby 200 case studies, this work demonstrates how simple models can be of greatbenefit. By examining real-world examples of how abstract ideas can be concrete-ly applied, this book explains how to transform any business or organization into ahigh-performance one where results are obtained, rather than imagined.


METRICS






Beyond the Balanced ScorecardImproving Business Intelligence with AnalyticsMark Graham Brown

"The Navy's carrier maintenance community continually improves their executionof highly complex aircraft carrier overhauls using Mr. Brown's metrics concepts tomeasure long-standing improvement efforts with 'cold, hard facts.' We rely on Mr.Brown's analytics as an integral part of our efforts."

— Dr. Jerry Blanton, AMSEC, Co-Founder, Carrier Team One

Most companies use some form of a scorecard to measure performance; yet,research suggests that the typical scorecard is based on unsophisticated measure-ments, resulting in misleading data. This volume details the right metrics for evalu-ating those aspects of performance not accurately tracked by most companies and government organizations.Through the text, mangers and quality control leaders can learn how to objectively measure customer rela-tionships, employee satisfaction, external business environments, and supplier performance, as well as strate-gy and financials.


The Pocket Guide to the Baldrige AwardCriteria15th Edition (5-Pack)Mark Graham Brown

The Baldrige criteria are being used by thousands of organizations around theworld to evaluate their progress toward becoming the best in their fields. This guideprovides the answers to the questions most commonly asked about the award andthe criteria. It also provides a brief explanation of each of the 18 items in theBaldrige criteria and lists the characteristics of organizations that excel in each ofthese 18 items.


Keeping ScoreUsing the Right Metrics to Drive World Class PerformanceMark Graham Brown

"Insightful and appropriate for organizations needing a new approach to work-ing smarter. The steps outlined for linking key success factors to performancemeasures help organizational leaders focus on measuring the right things theright way."

— Marie E. Artale, Customer Satisfaction Manager, IBM Corporation

"… delivers comprehensive and easy-to-understand guidelines for the develop-ment or tune-up of an organization's measurement system. Written with the sameuser-friendly clarity of his popular book, Baldrige Award Winning Quality, Brownmakes the overwhelming subject of measurement less intimidating through his step-by-step presentation."

— Julie S. Mehta, Performance Consultant, U.S. Coast Guard

Taking a balanced Baldrige approach, this book shows how to evaluate current approaches to measurementand pinpoint false measurements. It covers the selection of financial metrics, ways to measure employee andcustomer satisfaction, and methods to track performance and measure quality.


METRICS






Lean HospitalsImproving Quality, Patient Safety, and Employee SatisfactionMark Graban

“The concepts outlined in this book are the most powerful tools that I have everencountered to foster innovation, ownership, and accountability at the frontlinestaff level. This is a must-read for any leader in today’s increasingly complexhealthcare industry.”

— Brett Lee, PhD, FACHE, Vice President, Children’s Medical Center, Dallas

Winner of a Shingo Research and Professional Publication Prize, this book hasreceived universal acclaim from industry insiders as well as reform advocates.Drawing on his years of working with hospitals, Graban explains why and how Leancan be used to improve safety, quality, and efficiency in a healthcare setting. After highlighting the benefitsof Lean for patients, employees, physicians, and the hospital itself, he explains how Lean manufacturing sta-ples such as value stream mapping and process observation can help hospital personnel identify and elimi-nate waste in their processes, effectively preventing delays for patients, reducing wasted motion for caregivers,and improving quality of care.


Transforming HealthcareVirginia Mason Medical Center’s Pursuit of the Perfect PatientExperienceCharles Kenney

A chronicle of one of the most unique and impressive events in United Stateshealthcare, this book tells the story of a group of clinicians, administrators, frontlineworkers, trustees, and leaders, who blessed with vision, courage, and a relentlessdetermination to improve, worked together to make their medical center into anexample of efficiency and quality. Ultimately, it provides a new and possibly betterway to approach the healthcare delivery challenge, as it demonstrates that we don’thave to compromise on quality of care to achieve cost control.

Also check out 5S for Healthcare on page 25 by the consulting group responsible for the Virginia Mason plan.

Catalog no. PP7375, November 2010, c. 224 pp., ISBN: 978-1-56327-375-9, $39.95 / £25.99

Leading the Lean Healthcare JourneyDriving Culture Change to Increase ValueJoan Wellman, Pat Hagan, and Howard JeffriesSeattle Children's Hospital, Washington

Blending actual situations with practical theory, this book uniquely describes howthe healthcare value proposition can be changed by reducing waste, variation, andcomplexity in healthcare. It reveals the leadership tenacity and culture changerequired to remove waste from healthcare processes and eliminate the root causeof soaring costs, poor quality, poor safety, and limited access. It provides practical,applicable advice alongside personal and organizational stories and case studiestold by physicians and administrative leaders who are students of the ToyotaProduction System.

Catalog no. K11406, December 2010, c. 303 pp., Soft Cover, ISBN: 978-1-4398-2865-6, $59.95 / £38.99

INDUSTRIES / FUNCTIONS – HEALTHCARE






Optimizing Emergency Department ThroughputOperations Management Solutions for Health Care DecisionMakersJohn M. Shiver and David Eitel

“… gives the healthcare manager the tools needed to enhance the function of theEmergency Department …. The text is clear, concise and understandable to thoselacking a technical background but who still want to apply fairly sophisticatedtechniques to improving the patient experience and the productivity of ED staff.”

— J. Knox Singleton, President and CEO, Inova Health System

This landmark book provides senior-level emergency department (ED) managersand administrators with essential tools to make their job easier in the wake of anational crisis in ED capacity. It illustrates how information technology can play an important role in improv-ing the performance of the ED. It also demonstrates how to improve financial performance, specialty servic-es, and billing and collections functions. Because there are so many unpredictable elements related to theemergency room environment, this text explains how to predict patient volumes, flow, and space needs,using historical data to best plan for the unknowns.


Discharge Planning Handbook for HealthcareTop 10 Secrets to Unlocking a New Revenue PipelineAli Birjandi and Lisa M. Bragg

Hidden opportunities to improve profits in the healthcare industry abound in thearea of discharge planning. Based on 25 years of experience, Birjandi and Braggshow hospital administrators and directors how they can tap into new revenueusing the Six Sigma DMAIC model (Define, Measure, Analyze, Improve, andControl). The book includes a comprehensive case study, as well as a spreadsheetthat can be used to track success. Its step-by-step implementation strategy high-lights these five concepts:

• Redefine discharge planning

• Focus on the right metrics

• Use lean concepts for redesign

• Use a practical approach for improvement

• Create a culture that produces results


The Definitive Guide to Emergency DepartmentOperational ImprovementEmploying Lean Principles with Current ED Best Practices toCreate the “No Wait” DepartmentJoseph T. Crane and Charles E. Noon

Emergency departments were never designed to be the walk-in clinics they havebecome; yet, with so many having nowhere else to turn for care, ED’s have becomecauldrons of resentment in which neither the best needs of patient or hospital areserved. Offering a solution to this fiscal and medical madness, this step-by-stepguide shows how the application of Lean principles can lead to more efficient, cost-effective, and patient friendly departments. It brings together leading experts whodemonstrate the unique application of Lean tools and concepts to hospital operations and looks at those hos-pitals that have put this innovative approach into action.








Applying Lean in HealthcareA Collection of International Case StudiesEdited by

Joe Aherne and John Whelton

“For organizations looking for ideas as they embark on their Lean journey, thesecase studies provide wonderful examples and an opportunity to take a glimpseinto the many possibilities of Lean.”— Colleen Kennedy MLIS, MHA, Leader Physician Engagement, British Columbia, Canada

“.. a must buy for any healthcare professional interested in delivering improve-ment opportunities.”

— Eamon Counihan, Quality Co-ordinator, Bon Secours Health System, Ireland

Covering healthcare from clinical to nutritional services, this book provides a collection of international casestudies that demonstrate how Lean thinking can be applied in the healthcare industry. Offering an interna-tional perspective, the text introduces key concepts of Lean healthcare and presents real-life examples to illus-trate the practical benefits, such as increased patient satisfaction, and cost savings, that can result from a Leanphilosophy. The book features a number of expert contributors who offer practical tips. It also includes a fore-word from eminent psychiatry professor Jeffrey Clotheir, MD.

Catalog no. K11351, April 2010, 247 pp., ISBN: 978-1-4398-2739-0, $49.95 / £31.99

Comprehensive Healthcare for the U.S.An Idealized ModelWilliam F. Roth

Award-winning author Roth solicits the contributions of health workers fromaround the globe to examine the mire of technical quality and inefficient deliverythat has become the U.S. healthcare system. He looks at various challenges, dis-cussing how these are dealt with by 12 nations, all of which, according to WHO,rank higher than the U.S. in terms of services provided. Roth draws from the bestto design an idealized model for healthcare that would fit this country's uniquerequirements. Researched and referenced to satisfy policy professionals and admin-istrators, the book is lucidly written to engage all stakeholders with a fresh under-standing of what is valuable and viable.


The Pittsburgh Way to Efficient HealthcareImproving Patient Care Using Toyota Based MethodsNaida Grunden

"Every person who cares about modernizing health in America should read thisbook. If we could understand the Toyota system in health we would save thou-sands of lives and billions of dollars."

— Newt Gingrich, Former House Speaker, Founder, Center for Health Transformation

“At a time when we are overwhelmed by the staggering evidence that health caresystems that we depend on often fail us, here is a book that captures the power ofreal transformation.”

— Frank Christopher, PBS producer of the series “Remaking American Medicine.”

Grunden provides a look at how principles borrowed from industry—in specific Toyota’s concept of Lean man-ufacturing—can be applied to make healthcare safer, as well as more effective and less costly. She compilescase studies from units in different hospitals around the Pittsburgh region that successfully applied industrialprinciples to the benefit of patients and the satisfaction of employees. This book has received rave reviewsfrom a large number of public policy and health experts.








5S for HealthcareJ. Michael Rona Consulting Group LLC

Series: Lean Tools for Healthcare Series

Based on Hiroyuki Hirano's classic 5 Pillars of the Visual Workplace and modeledafter the Shingo Prize-winning Shopfloor Series for Lean Manufacturers, this workadopts a proven reader-friendly format to impart all the information needed tounderstand and efficiently implement Lean methodology in a healthcare setting.Written by the principals involved with the Rona Consulting Group, who wereresponsible for the groundbreaking implementation of the Toyota ProductionSystem at the Virginia Mason Medical Center, it provides a wealth of transferableexamples along with a step-by-step hands-on guide that will demonstrate how toget an entire organization positively involved in the process.

Catalog no. K10196, January 2010, 120 pp., Soft Cover, ISBN: 978-1-4398-0350-9, $28.95 / £18.99

Kaizen for Lean HealthcareThomas L. Jackson

Series: Lean Tools for Healthcare Series

This user-friendly book, written by a member of the J. Michael Rona ConsultingGroup, is designed to improve understanding of kaizen as it applies to healthcaresettings. It describes what a kaizen event is and explains all the phases necessary tolearning and implementing continuous improvement practices by a group of indi-viduals to a targeted area within a specified time period. It also outlines how to pre-pare a presentation and circulate and display results using Lean implementations.This text aids in the understanding of concepts and theories through the use ofmargin notes that reveal important information, key terms and points, healthcareexamples, and how to steps.

Catalog no. K11931, June 2011, c. 120 pp., Soft Cover, ISBN: 978-1-4398-4152-5, $28.95 / £18.99

Value Stream Mapping for Healthcare MadeEasyCindy Jimmerson

"… an invaluable resource for all involved in implementation of Lean inHealthcare. … Jimmerson has demystified the value stream map and made it anactionable tool for all!"

— Mimi Falbo, Mimi Falbo LLC

"I would highly recommend this book to anyone desiring to genuinely adopt theToyota approach to the healthcare industry and to do so with confidence. This isthe real deal."

— Ken Pilone, President, Sterling Methods Consulting Group, LLC

This manual introduces readers to the simple but essential Value Stream Map (VSM). It offers an easy-to-learnintroduction to VSMs that will enable readers to look at any process with different eyes. The book also high-lights simple to use data collection and interpretation as part of the VSM process.








A3 Problem Solving for HealthcareA Practical Method for Eliminating WasteCindy Jimmerson

"What a great book to address a huge gap in healthcare process improvement!Having a source book to teach continuous change and illustrate waste reductionbased on the Toyota Production System to busy healthcare practitioners has beensorely lacking until now. I have used the A3 in my hospital and it works! Clinicalworkers can see the entire project on one piece of paper as well as areas of obvi-ous waste."

—James Nesbitt, MD, MMM, Project Manager, Providence Alaska Medical Center

Written by an expert in Lean principles, this book offers an easy-to-use problem-solving method that can be applied to every aspect of healthcare to identify, understand, and improveprocesses. Illustrated with numerous A3s in various stages of development, this practical, easy-to-use work-book explains how to extend the value stream mapping philosophy to the more focused perspective of thesingle page A3 report.


Essentials for the Improvement of HealthcareUsing Lean & Six SigmaD.H. Stamatis

By using theories of Six Sigma and Lean methodology, this text presents solutionsto fundamental problems in healthcare. This text breaks the system down into threefundamental areas: primary care, hospitals, and managed care. The author identi-fies the four critical issues that affect healthcare as it relates to efficiency and cost byaddressing the specific issues. The book discusses the application of IT in healthcareas a tool of improvement, and how to select the best project for improvement. Theauthor also includes a discussion of ISO and the Malcolm Baldrige award. Casestudies are included to illustrate successes.


Leveraging Lean in HealthcareTransforming Your Enterprise into a High Quality Patient CareDelivery SystemCharlie Protzman, George Mayzell, and Joyce Kerpchar

Expanding on the concepts and tools of Lean hospitals and coupling these ideaswith the principles of Six Sigma, this book presents a how-to guide to true efficiencyin hospitals. Beginning with an overview and description of Lean tools, such asToyota and Gilbreth and Taylor, it demonstrates Lean implementation at every levelof a hospital including the ED, OR, Radiology, and Cath Lab. The authors discusstraditional methods and typical problems, look at a value stream map for each area,and provide actionable blueprints and case studies to facilitate Lean improvements.








Safer Hospital CareStrategies for Continuous InnovationDev Raheja

An examination of the effectiveness of present hospital care methods, this bookillustrates how to find simple, comprehensive solutions that produce high return oninvestment. It emphasizes innovative techniques, proven safety methods, modelsfor risk managers, heuristics for leading change, reliability methods that deliverright care over time, dangers in medical devices for critical care, and techniques forgiving care with speed and efficiency without compromising safety. Experts fromthe aviation industry, world-class organizations such as Toyota and General Electric,and innovative hospitals such as Johns Hopkins offer their insight.


Performance Based MedicineCreating the High Performance Network to Optimize ManagedCare RelationshipsWilliam J. DeMarco

Highlighting quality driven issues and the power behind pay for performance andvalue-based benefit designs, this book provides the knowledge to establish per-formance based structures, such as quality measurement, incentive payment struc-ture, and incentive size, within an existing organization. Focusing on how to imple-ment new designs and how to create strategies to measure performance andimprove efficiency, it discusses how to create value and optimize payment and mar-ket share. It also describes the trade off of systems and IT investments by providersand payers to gain incremental quality improvement.

Catalog no. K10654, January 2011, c. 300 pp., ISBN: 978-1-4398-1288-4, $69.95 / £44.99

Medical Error and HarmUnderstanding, Prevention, and ControlMilos Jenicek

Presenting the work of long time physician and teacher, this book provides a thor-ough investigation into medical error. It presents a short history of error in generalacross various domains of human activity, and then explores approaches used toinvestigate and ameliorate errors in medicine and other health sciences. The bookalso discusses whether dealing with errors is a learned skill and looks at how muchof the problem with medical error is caused by the medical community’s failure toteach and understand everything there is to know about medical error, includingthe often neglected importance of critical thinking skills.It also considers the physi-cian’s growing role in tort litigation.

Catalog no. K11671, July 2010, 384 pp., ISBN: 978-1-4398-3694-1, $79.95 / £49.99







Health Care Will Not Reform ItselfA User's Guide to Refocusing and Reforming American Health CareGeorge C. Halvorson

"Students of health reform would do well to consider this book as an invaluabletext for our national public policy debate."

— Tom Daschle, Former U.S. Senate Majority Leader

"This hard hitting and practical blueprint for reforming medicine will work if welisten. I even took notes."— Dr. Mehmet Oz, Vice Chair and Professor of Surgery, Columbia University; Oprah Radio

Written by the CEO of the largest healthcare provider in the nation, this book pro-vides a basic primer on the American health care system. Making use of insightful anecdotes and examples,Halvorson cuts through the rhetoric to offer a blueprint for achieving real improvements in health care deliv-ery. He explains how health insurance works in the U.S. compared with the rest of the world and outlines thebarriers to American reform.

Catalog no. K10830, 2009, 184 pp., ISBN: 978-1-4398-1614-1, $29.95 / £19.99

Governance for Health Care ProvidersThe Call to LeadershipEdited by

David B. Nash, William J. Oetgen, and Valerie P. Pracilio

"… essential reading for all physicians who are about to embark on the journey ofgovernance. I for sure will recommend this book to the physicians on my hospitalboard."

— ACMQ Focus

Physicians, nurses, pharmacists, and other medical professionals who serve on theboards of private, nonprofit institutions often do so with much more diligence thanknowledge. Very little material exists to cover the range of issues that are so vital ata time when health care institutions face patient overloads and budget shortages. Written by leading healthcare advocates and authorities, this volume provides a readily accessible resource that helps define the func-tions of a board member and summarizes the problems that they most likely will face including finance andcompliance issues, as well as funding and strategic planning.


Healthcare TransformationA Guide for the Hospital Board MemberMaulik Joshi and Bernard Horak

"This book is a ‘must-read’ resource for Hospital Management Teams and Boardmembers. The content is supported by extensive knowledge and practical currentexperience of the authors."

— Alexander (Rusty) Sloan, MD, MACP, Lt. General, USAF, Retired

Designed for easy reference by people with busy schedules, this concise manualprovides hospital board members and executives with practical guidance on howto become actively engaged in the transformation of their organization. It focuseson how the healthcare industry as a whole is transforming and stresses the impor-tance of having board members who are able to provide leadership. The manual is ideal for orienting newboard members and for providing experienced members with insight on key issues. It supplies questions toask stakeholders that will facilitate engagement. Each chapter is organized around action steps designed tobuild organizational quality and facilitate change.








Healthcare Delivery in the U.S.A.An IntroductionMargaret F. Schulte

“This book would be helpful for those early in their careers or transitioning in fromother industries to help improve quality and processes. I certainly wish I had thisguide when I was starting in healthcare.”— Mark Graban, Senior Lean Consultant, ValuMetrix Services, Ortho Clinical Diagnostics,

Inc., Author of Lean Hospitals

The position of the medical sector as a growth market is opening new avenues forworkers outside the traditional realm of healthcare, such as management engineers,IT professionals, and process improvement specialists. A guide for healthcare mar-ket entrants, this book equips new hires with the knowledge needed to navigate the business of medicine. Italso provides a much-needed orientation to the broader healthcare work environment for those working inhospitals or as vendors and manufacturers. The author, editor of the American College of Health Executive’sFrontiers in Health Services Management, confronts challenges facing the industry as a whole, includingfinance, legal, regulatory, and workforce issues.


Paradox and Imperatives in Health CareHow Efficiency, Effectiveness, and E-Transformation CanConquer Waste and Optimize QualityJeffrey C. Bauer and Mark Hagland

“... puts the health care industry’s biggest challenges into a fresh and useful per-spective. ... Through numerous case studies, the authors show how successfulhealth care organizations are using performance-improvement tools to producetop-quality services as inexpensively as possible.”

— QualityDigest

In this groundbreaking critically acclaimed collaboration, Bauer and Haglandexplain why providers must draw upon internal resources to increase net revenueand provide the quality of care that payers and consumers are demanding. Through numerous case studies,the authors show how pioneering health care organizations are using performance improvement tools—including Lean management, Six Sigma, and the Toyota Production System—to produce excellent services asinexpensively as possible. This book challenges health care leaders to change their status quo mentality andto put their organizations on a positive path… while redirection is still possible.


Successful Collaboration in HealthcareA Guide for Physicians, Nurses and Clinical DocumentationSpecialistsColleen M. Stukenberg

“Colleen is a recognized expert in the field of Clinical DocumentationImprovement. Anyone interested in implementing a successful ClinicalDocumentation Improvement Program should read this book before starting theprocess."

— Lynne Spryszak, RN, CCDS, CPC-A, Manager, Precyse Solutions, LLC

A guide for healthcare providers to forge alliances that will improve patient care,this book describes ways in which nurses and physicians can collaborate to enhancesafety, quality, and treatment efficacy, and how this collaboration can have positive financial effects. It demon-strates how cooperation can meet the changing requirements of governing bodies and government regula-tions as well as technological advancements. It addresses the roles of direct patient caregiver, charge or teamleader nurse, case manager, and clinical documentation specialist, and covers regulatory and financial topicssuch as Recovery Audit Contractors (RAC) and Pay for Performance.








Dynamic Capacity Management for HospitalsAdvanced Methods and Tools for OptimizationPierce Story

Presenting new approaches, tools, and perspectives, this book facilitates the effec-tive management of the complexities and dynamism unique to health care opera-tions. It introduces health care managers and professionals to state-of-the-art con-cepts designed to improve both process- and dynamic systems-focused perform-ance and develop appropriately dynamic process-level solutions to complex sys-tems level issues. Employing common methodologies such as Lean, Six Sigma, andCQI, the "Dynamic Capacity Management" approach addresses the analysis andimprovement of hospital- and department-wide capacity, patient flow, resourceallocation, and performance optimization.


Healthcare Payment SystemsFee Schedule Payment SystemDuane C. Abbey

Following Healthcare Payment Systems: An Introduction, this second volume in aseries by medical payment expert Duane Abbey provides an overview and discus-sion of the various fee schedule payment systems used by healthcare providers andthird party payers. Designed for hands-on use by providers and their fiscal agents,emphasis is placed on the basic elements of any fee schedule payment systemalong with the myriad variations that exist to garner payment for physician servic-es, ambulance services, durable medical equipment, prosthetic and orthotics, lab-oratory services, physical and occupational therapy and associated services, and/ormedical products. This volume offers special attention to the Medicare PhysicianFee Schedule.


The Medicare Recovery Audit ContractorProgramA Survival Guide for Healthcare ProvidersDuane C. Abbey

Written by medical billing guru, Duane Abbey, this volume explains all that isrequired to prepare and successfully defend against RAC audit recoveries. Using thesame succinct style that always makes his writing so accessible, Abbey illustrates hislessons with simple case studies placed in the context of a fictitious communitywhose population is served by a hospital, clinics, a nursing facility, and otherproviders all seeking to maintain compliance and profitability. In discussing RACguidelines, this resource —

• Shows how to identify overpayment areas and associated compliance issues

• Addresses resource requirements including new personnel, such as RAC specialists

• Includes planning models for developing compliance departments

• Provides an extensive glossary to make sense of medical billing’s alphabet soup of acronyms

Catalog no. K11113, February 2010, 124 pp., Soft Cover, ISBN: 978-1-4398-2100-8, $59.95 / £38.99







The Physician Employment Contract HandbookSecond EditionA Guide to Structuring Equitable ArrangmentsMaria Todd

This revised and updated edition provides an invaluable resource for physicians whoare looking to sell their practice and for health systems who wish to become affili-ated with a group practice or who are interested in contracting with physicians. Thebook provides sample physician employment contracts and explains how each con-tract works. Written by an expert in the field of physician contracting, the text dis-cusses the various legal and compliance issues related to physician employment,such as anti-self referral and anti-kickback issues, and examines how to resolve dis-putes through arbitration or mediation. The author also outlines the pros and cons of various partnershiparrangements.

Catalog no. K10674, March 2011, c. 275 pp., Soft Cover, ISBN: 978-1-4398-1316-4, $89.95 / £57.99

Transformative QualityThe Emerging Revolution in Health Care PerformanceMark Hagland

Looking for ways to improve quality and cut costs, healthcare organizations are inthe midst of overhauling all of their operational systems, as they seek to achieveheightened levels of quality. After providing a historical perspective and an analysisof the changing demands and demographics behind this current push, notedhealthcare write Mark Hagland provides a thorough look at in-depth case studiesinvolving dramatic transformations in health delivery systems of varying complexi-ty. Hagland also looks at the role of information technology in these transformationsand discusses likely outcomes and future trends.


Workplace Clinics and Employer ManagedHealthcareA Catalyst for Cost Savings and Improved ProductivityA. Michael La Penna

The advent of organizations considering an on-site approach to the delivery ofhealthcare services increases in direct proportion to the rising of healthcare costs.This volume is a how-to manual on the design and implementation of an on-siteprogram and presents the challenges and benefits of such a system. Topics dis-cussed include hospital and specialty contracting; employee choice concerns; cost-control; ancillary services such as pharmacy, lab testing, physical therapy, and imag-ing; workers compensation issues; benefits consultants; quality vs. value analysis;and other considerations. A case study is provided that follows the implementation of a program from incep-tion to introduction.








Consumer Directed Health CareA 360 Degree ViewKim Slocum

“…a top-notch synthesis of credible research on health care in the United States.… It is a must-read and a call to action for persons in policy and leadership posi-tions in and out of health care and for anyone who wants to make sense of thecomplex dilemma in which US health care finds itself.”

—Margaret F. Schulte, DBA, FACHE, Editor, Frontiers of Health Services Management

Drawing from three decades of experience in a variety of healthcare, pharmaceuti-cal, and biotechnology firms, respected healthcare consultant, Kim Slocum appliesa uniquely broad viewpoint to the U.S. healthcare crisis. He discusses how the sys-tem has evolved and debunks various myths that continue to persist. Exploring potential solutions, he bal-ances many diverse and conflicting factors, including the movement to make healthcare more patient-cen-tered and the growing trend to transfer significant portions of financial risk to patients via high-deductibles.Slocum closes the book by discussing what a successful consumer-directed system might look like and whatsteps would be required to make it happen.


Pursuing Excellence in HealthcarePreserving America's Academic Medical CentersArthur M. Feldman

"… a terrific resource for anyone interested in understanding the indispensablerole of the academic health center. … Dr. Feldman identifies the key problems weneed to solve and the kinds of solutions we must adopt to ensure the excellence ofour essential missions in research, training, and health care going forward. A bookall health care leaders should read and then read again."

— Michael M.E. Johns, MD, Chancellor, Emory University

For over 100 years, academic medical centers (AMCs) have been the bastion ofmedicine; providing outstanding care, incubating the discoveries that haveimproved healthcare around the world, and training the next generation of doctors and scientists. Delineatingthe issues that have lead to the current crisis in AMCs, this book presents an in depth analysis of the issuesand challenges facing AMCs and offers recommendations that allow them to achieve their core mission —the delivery of outstanding patient care.


Statistical Analysis for Decision Makers inHealthcareSecond EditionUnderstanding and Evaluating Critical Information inChanging TimesJeffrey C. Bauer

Designed for the busy healthcare professional who needs to collect, analyze, and/orevaluate data, this readily accessible work explains the fundamental concepts, uses,and misuses of statistics. Without jargon or mathematical formulas, the authorintroduces the practice of quantitative analysis to provide an understanding of theprinciples of scientific inquiry, applied to clinical medicine, program evaluation, pol-icy analysis, management, accounting, and research. The book discusses practical scientific methods to showwhy statistics cannot compensate for bad science or bad data. It will help readers to intelligently evaluate themany numbers that cross their desk in the normal course of business.








Lean Office and Service SimplifiedThe Definitive How-To GuideDrew Locher

A comprehensive reference, this unique book covers all of the relevant conceptspertaining to the coinciding realms of value stream mapping and the Lean office.Providing extensive detail regarding the application of Lean thinking to office andservices, this book describes value stream management, standard work, flow, andpull. It defines specific how-to methodologies in exhaustive depth, breaks down keyLean concepts into their elementary components and describes them in the con-text of office and services, provides implementation strategies on a function-by-function or department-by-department basis, and includes detailed examplesthroughout.


Creating the Ultimate Lean OfficeA Zero-Waste Environment with Process AutomationRaymond S. Louis

All businesses are dependent on cost-incurring office and administrative processes.In Creating the Ultimate Lean Office, Raymond Louis takes the definition ofwaste a step further than one finds in Lean manufacturing. Louis defines any officeactivity, even if it adds value, as wasteful if it is manually performed when it can becost-effectively automated. He calls the technique to eliminate manually performedactivities administration automation. This technique encourages the design of auto-mated processes to meet the needs of specific environments. This book, in thehands of an improvement team applying due diligence, will create a Lean officethat can compete with the best organizations in the world.


Lean Human ResourcesRedesigning HR Processes for a Culture of ContinuousImprovementCheryl M. Jekiel

“Jekiel makes a strong case for the greater part of waste coming from poor or non-existent HR systems; … Her systematic mapping of the path to get out of the caveand into the light of day gives the reader hope that transformation of the cultureis possible.”

— Sherrie Ford, Chairman, Executive VP, Culture Power Partners, Inc.

Ultimately, lasting change requires evolution in organizational cultural and toachieve such change requires definitive changes in behavior. Jekiel, who has beenimplementing Lean initiatives out of HR offices for 20 years, puts forth a proven five-year plan that includesthe building of improvement-linked competencies into each job. A unique approach to continual improve-ment, this volume offers companies the means to maximize employee potential by first showing them howto increase the improvement power of their HR departments. A final section is designed especially for CEOswho must address their own views of HR before addressing improvement.


INDUSTRIES / FUNCTIONS – OFFICE






The Kaizen Event PlannerAchieving Rapid Improvement in Office, Service, and TechnicalEnvironmentsKaren Martin and Mike Osterling

"This book will be of great benefit to any leader in the planning of kaizen events… I plan to purchase a copy for each of our managers and Lean facilitators."

— Chat Norvell, President and CEO, CarePartners

A practical how-to guide, this book takes readers through the ins and outs of plan-ning and executing kaizen events in non-manufacturing settings and conductingpost-event follow-up to sustain changes made. The authors provide methods andtools to help build a motivated workforce and lay a foundation for continuousimprovement. Readers will learn how to effectively scope the activity, engage the right people, and facilitateevents with measureable results. The clear, concise presentation allows beginners and experienced practi-tioners to venture into non-manufacturing environments with comfort and ease. An accompanying CD pro-vides immediate access to a number of Excel-based tools.


Flow in the OfficeImplementing and Sustaining Lean ImprovementsCarlos Venegas

“Whether readers are interested in a specific topic, say kaizen, or have committedthemselves to launching Lean in their workplaces, they will discover useful nuggetsin Flow in the Office that help them combine their current thinking with the pos-sibilities of what Lean can do for their businesses."

— Sir Read A Lot

For years, Lean initiatives have generated staggering improvements on the shopfloor. And now many business leaders want these Lean benefits incorporated intonon-traditional environments. This book demonstrates how to efficiently translateand transition Lean manufacturing principles into any office. In this work, Carlos Venegas confirms that thecompetitive advantage will go to those who manage information most effectively and efficiently. It is notenough to be a Lean manufacturer; you need to be a Lean business. The author translates the language ofLean Manufacturing into the language of Lean Office Flow, bringing bits, bytes, and conversations into theconcrete world of process improvement.


Metrics-Based Process MappingAn Excel-Based SolutionKaren Martin and Mike Osterling

Metrics-based Process Mapping (MBPM) is a process-design methodology thatcombines the cross-functional aspects of traditional swim-lane process maps withthe key time and quality metrics incorporated within Value Stream Maps. Especiallyeffective for analyzing and designing office, service, and technical processes, thisCD contains an Excel-based tool to electronically archive and distribute current andfuture state MBPMs that have been created manually in a cross-functional team set-ting. The tool includes a custom toolbar to ease the mapping process and an auto-calculation feature that compares current and future state process performancemetrics. Easy to use with no installation necessary, the tool requires only basic Excelexperience. It includes a detailed instruction guide that walks users through the process of creating a metrics-based process map.

Catalog no. PP7380, 2009, CD-ROM, ISBN: 978-1-56327-380-3, $157.95 / £99.00







5S for the OfficeOrganizing the Workplace to Eliminate WasteThomas Fabrizio and Don Tapping

"… more than a book about 5S in the office … encompasses a total facility-wideprocess of implementing and sustaining improvements that will last. … The check-list, and form examples are just what is needed to help your organization brain-storm what will work best in your environment."

— Mary E. Murphy, Haldex Way Change Agent, Kansas City, Missouri

Fabrizio and Tapping bring the concepts of Hiroyuki Hirano’s 5S System into theoffice. The activities at the heart of this process include organizing, ordering, clean-ing, standardizing, and their sustainment. More than a book about the office; thiscritically acclaimed work elaborates a total facility-wide process for implementing and sustaining improve-ments, while also demonstrating the importance of senior management’s participation. An accompanying CDcontains computer-usable blank versions of forms and worksheets that appear in the book.


Value Stream Management for the Lean OfficeEight Steps to Planning, Mapping, & Sustaining LeanImprovements in Administrative AreasDon Tapping and Tom Shuker

"We have been on our Lean journey in manufacturing for some time now, and areexpanding that success … across administration for the entire company. … Wepurchased the Value Stream Management for the Lean Office workbook for all900+ leaders. … These workbooks were an outstanding hit and I re-ordered sev-eral times to make sure everyone who needed one, received one!"

— David Speer, Corporate Director, LeanSigma®, Maytag Corporation

Extending their eight-step process to the realization of a Lean office, Tapping andShuker use a customer service case study to illustrate the effectiveness of the value stream storyboard. In addi-tion to providing a thorough overview of basic Lean concepts, the book details methods for identifyingadministrative activities in need of attention.

Includes a Lean assessment tool, a storyboard template, charts, a team charter, and worksheets


The Complete Lean EnterpriseValue Stream Mapping for Administrative and Office ProcessesBeau Keyte and Drew Locher

"Keyte and Locher have provided a valuable contribution for identifying strategicoperational value streams for administrative and office processes. They demon-strate that the next generation of waste identification and elimination is in thebusiness support functions."

— Dr. Ross E. Robson, Executive Director, Shingo Prize, Utah State University

Winner of a Shingo Prize for Excellence in Manufacturing Research, this manual offersa step-by-step approach to applying Lean initiatives to the administrative and officeenvironment. Written for leaders looking to improve production support activitieswithin their order-to-cash value stream, this volume provides a valuable tool for applying value stream map-ping to non-production areas. It helps identify office wastes, establish performance metrics, and speed upadministrative workflow, so as to improve office efficiency.








Lean Six Sigma for the OfficeJames William Martin

Historically, the integration of manufacturing methodologies into the office envi-ronment has proven problematic. As a solution, Six Sigma guru James Martin pres-ents proven modifications that can be properly deployed in offices, particularlythose offices involved with global operations. Making use of kaizen and Six Sigmaconcepts, along with Lean manufacturing principles, he instructs managers on howthey can improve operational efficiency and increase customer satisfaction. Utilizingsummarizing tables and operational roadmaps, he demonstrates how simple andstandardized processes can be adopted to improve efficiency and eliminate costlymistakes.

Introduces Minitab® Quality Companion and Crystal Ball® Software

Catalog no. AU6879, 2009, 348 pp., ISBN: 978-1-4200-6879-5, $52.95 / £33.99

Lean AdministrationCase Studies in Leadership and ImprovementEdited by

Association for Manufacturing Excellence

Responding to the growing interest in applying Lean to non-manufacturing opera-tions, this first volume of the Enterprise Excellence Series covers the implementationof Lean in administrative and office applications. Drawing on case studies fromAME’s Target Magazine, it provides a practical, in-depth description of Lean officesimplementations, most of which have not been described in other publications.Offering real-world Lean office information, the case studies included are catego-rized into three areas: Leadership, Organization and Training; Improving Processes;and Lean in Healthcare.


Freedom from Command and ControlRethinking Management for Lean ServiceJohn Seddon

"… John Seddon provides a key to the wise and the brave that can unlock theirpeople, their customers and their profits. Do you have the faith, bravery and con-viction to use it?"

— Bruce MacLellan, Director, Customer Contact, Capital One

Proving that top-down decision-making within service-oriented businesses leads tomanagers who are detached from employees and daily operations, John Seddondemonstrates that decision-making based on purpose-related measures (such asputting customers first and improving services) can help managers reconnect withoperations, see waste, and exploit opportunities for improvement. Through case material, this ToyotaProduction Systems adherent illustrates how systems thinking leads to improved service, revenues, and staffmorale. He also posits that the service industry fundamentally differs from manufacturing, and shows howToyota production principles can be applied in that arena.








Lean Higher EducationIncreasing the Value and Performance of University ProcessesWilliam K. Balzer

"… a must read for all university administrators–it helps them build processes andservices that truly serve students."

— Tom Andrews, BGSU Firelands College

This book is designed to teach academic administrators how to apply Lean businessprinciples to the successful running of their institutions. It returns education to theconsumers it was designed to serve: the students. Applying voice of the customer(VOC) concepts, it introduces educators to Lean tools, such as value stream map-ping. Relying on concepts inherent in all Lean processes, it focuses on involvingstakeholders and holding them accountable for the delivery of quality every step of the way.

Catalog no. K10754, April 2010, 312 pp., Soft Cover, ISBN: 978-1-4398-1465-9, $49.95 / £31.99

Organizational Assessment and Improvement inthe Public SectorKathleen M. Immordino

Series: ASPA Series in Public Administration and Public Policy

In order to implement an integrated cycle of assessment, planning, and improve-ment, government agencies need a framework for organizational assessment thatspeaks to their unique needs. This book provides those who manage or work ingovernment with an understanding of and a methodology for assessment. Thebook introduces the assessment concept and its significance in public organiza-tions. It then focuses on procedures and demonstrates how communication thatresults from an assessment process can create a widely accepted case for change.The text presents a model grounded in the Malcolm Baldrige National Quality criteria but adapted for the lan-guage and culture of government organizations.

Catalog no. AU4208, January 2010, 248 pp., ISBN: 978-1-4200-8420-7, $59.95 / £38.99

Lean for the Public SectorThe Pursuit of Perfection in Government ServicesBert Teeuwen

Written specifically to address the application of Lean practices in government andthe public sector, this highly original reference covers the basic philosophy of Leanbefore detailing specific methods to improve processes in the public sector. Itaddresses concerns unique to the public sector environment and considers the roleof the citizen, not only as customer, but as a voter, taxpayer, and community par-ticipant. The approach provides a more reality-based view of value-added servicesand waste in the public sector. The text also includes many explanations of Leanprinciples and methods, examples, and international case studies.








Lean ITEnabling and Sustaining Your Lean TransformationSteven C. Bell and Michael A. Orzen

“There has never been a more critical time to improve how IT integrates with theglobal business enterprise. This book provides an unprecedented look at the rolethat Lean will play in making this revolutionary shift and the critical steps for sus-tained success.”

— Steve Castellanos, Lean Enterprise Director; Nike, Inc.

To achieve and sustain a Lean transformation, organizations must effectivelyengage and leverage IT in all aspects of continuous improvement. This work exam-ines how IT can better understand and serve the needs of the business; how thebusiness can engage IT in continuous improvement activity; how IT can apply the tools and methods of Leaninwardly; and how to measure the results of these efforts. The authors provide diagrams and tables depictingmethods, practical examples, and case studies.

Catalog no. K10912, September 2010, 360 pp., ISBN: 978-1-4398-1756-8, $49.95 / £31.99

Thin AirHow Wireless Technology Supports Lean InitiativesDann Anthony Maurno and Louis Sirico

“A must read for executives looking to optimize performance while automatingtraceability in outsourced supplier networks.”

—Raj Saksena, President and CEO, Omnitrol Networks Inc.

Drawing on success stories from dozens of diverse companies, this hands-onresource discusses the application of a wide range of wireless technologies, includ-ing RFID, wireless sensor networks, real-time location systems, and GPS. It address-es the modernization of infrastructure, elimination of costly hardware and redun-dant equipment, and the provision of real-time visibility.

Provides access to a Lean Wireless ROI Calculator you can use to factor in variables specific to your company so as tocalculate possible savings

Catalog no. K10242, April 2010, c. 251 pp., ISBN: 978-1-4398-0439-1, $59.95 / £38.99

Far from the FactoryLean for the Information AgeGeorge Gonzalez-Rivas and Linus Larsson

“It’s one thing to develop a concept. It’s another to make it sing. This is the hym-nal.”

— Dr. Don V. Steward, CEO, Problematics; inventor of DSM

“Excellent guidance for leaders and workers in office and project environments,and a 'must read' for CIOs everywhere.”

— Julian Amey, Principal Fellow, Warwick University

If you employ knowledge workers who do most of their work with computers, thenthis book is for you. Quite simply, it's for any organization with a lot of Web DNAthat wishes to cut costs, improve performance, and stay perpetually competitive.

Catalog no. PP9456, September 2010, 325 pp., Soft Cover, ISBN: 978-1-4200-9456-5, $49.95 / £31.99

INDUSTRIES / FUNCTIONS – IT






Lean ConnectionsMaking Information Flow Efficiently and EffectivelyChris Harris and Rick Harris

Employing a workbook format, this manual follows RNA Manufacturing, a fictionalcompany, through its implementation of a comprehensive Lean production system.As the authors outline RNA’s methods and thought processes, they employ exer-cises that ask questions about your own production system, the same questionsthat they would ask you if they were standing in your facility as consultants. Yourchallenge is to think deeply about the answers, as well as the changes needed tomake information flow both ways—

• From the end customer through materials control to the production floor

• On the production floor at the operator, team, and value stream level

• And then from the production floor through the extended value stream


Lean Software StrategiesProven Techniques for Managers and DevelopersPeter Middleton and James Sutton

"Outstanding! A must read for software practitioners and technical leaders con-cerned with incorporating integrity and positive attributes into integrated systemsdesign."

— Barry Hendrix, Technical Fellow, Lockheed Martin

Winner of a Shingo Prize for Excellence in Manufacturing Research, this resourceshows how the most advanced concepts of Lean production can be applied to thesoftware development industry. Written for software engineers, developers, andproject managers involved with creating Lean software processes and executinggenuinely Lean projects, this book shows why many of the typical processes employed in software develop-ment are simply inadequate and can be enhanced by Lean. It draws on the personal experiences of the twoauthors as well as research on various software companies applying Lean production principles and tools insoftware development, especially for complex systems.


Easier, Simpler, FasterSystems Strategy for Lean ITJean Cunningham and Duane Jones

"For too long IT systems have indirectly functioned as a barrier to Lean initiatives.... This book breaks new ground because the authors fully illustrate just how IT cansignificantly hasten waste reduction."

— Anand Sharma, President and CEO, TBM Consulting Group, Inc.

To enhance its Lean journey, a company must implement information systems thatfully support the Lean initiative. In this book, Cunningham and Jones introduce acase study of an actual Lean implementation involving an IT system of a mid-sizemanufacturer, highlighting the IT issues faced during Lean transformation. Thebook suggests changes that will be required in an information system to make it a partner with, rather thana barrier to, a company becoming a Lean enterprise. It showcases opportunities that will arise for the infor-mation systems team to eliminate waste and apply Lean principles in its own operations.








Customer Satisfaction PlanningEnsuring Product Quality and Safety Within Your MRP/ERPSystemsThomas T. Hirata

This book presents a progressive, cost-cutting efficiency system that builds on mate-rial requirement planning (MRP) and enterprise resource planning (ERP) to facilitateimproved customer satisfaction. It illustrates how shifting focus from inventoryreplenishment to customer service results in a better product, received exactly ontime, at projected cost. The author elaborates on the classic "5 Whys" technique asit applies to customer satisfaction planning (CSP), explains manufacturing systemevolution, looks at how to establish and personalize the customer relationship aswell as rate and forecast clients, and presents examples of CSP in action.Furthermore, he explains why his novel system will change the face of modern business management, offersan implementation plan, and documents the adjustments in logic and strategy required to make majoradvances in inventory management and product assurance.


A Tale of Two SystemsLean and Agile Software Development for Business LeadersMichael K. Levine

"In the epilogue, Levine summarizes the lessons leaders should take away from thiswonderful tale. This chapter alone is worth the price of the book; following thestory brings a deep appreciation of its wisdom."— Mary Poppendieck, author of Implementing Lean Software Development: From Concept to

Cash

This book considers two fictional systems development projects. One project provesto be an abject and expensive failure, while the other succeeds in creating a majornew revenue stream and solving important customer needs. Contrasting the meth-ods employed in a traditional, process-centric waterfall approach, with a Lean and agile-inspired approach,this book provides business leaders with a tangible understanding of why Lean thinking is so well-suited tocontemporary environments requiring flexibility, speed, and the input of specialized knowledge.

Catalog no. K10217, 2009, 344 pp., ISBN: 978-1-4398-0389-9, $49.95 / £31.99

Lean Performance ERP Project ManagementImplementing the Virtual Lean Enterprise, Second EditionBrian J. Carroll

Series: Resource Management

Based on the author’s years of practical experience, this book presents a projectmanagement methodology that integrates strategy, people, process, IT, and Leanto manage the project implementation of a Virtual Lean Enterprise. Employing aconversational tone, it demonstrates the need to connect Lean performance withIT to achieve maximum Lean benefits, then discusses the best business processmethodologies and ways to integrate them, including a Lean tool kit that requiresparticipation from all departments of an organization

• Provides project managers with an overview to present to Lean transformation committees

• Presents a strategy for ERP project managers dealing with Chinese-based manufacturing

• Discusses current events in the transition to Lean in the global economy

• Includes new developments such as e-kanban and RFID

• Features a case study of the Lean Commerce system implemented by Toyota North America








Practical Lean AccountingA Proven System for Measuring and Managing the LeanEnterpriseBrian H. Maskell and Bruce Baggaley

"… a highly readable and uncomplicated guide for financial and other managersof Lean companies … an invaluable reference for years to come."

— Fred Garbinski, Parker Hannifin Corporation

With a value stream approach at its core, this book demonstrates how to transforma traditional accounting system to support a company's Lean initiative. The authorsdefine the principles of Lean accounting and demonstrate ways to identify andeliminate wasteful transactions. They cover cell performance measurement, use ofthe box score, operational and financial planning, cost targeting, Lean accounting diagnostics, and valuestream mapping. An included CD provides needed forms and charts. Designed as a hands-on manual forfinancial officers that will continue to serve as a resource following conversion, the book can also be used towin over a skeptical finance department.

Look for a new edition of Practical Lean Accounting coming in the spring of 2011 – ISBN: 978-1-4398-1716-2


Making the Numbers CountSecond EditionThe Accountant as Change Agent on the World-Class TeamBrian H. Maskell

With his energetic tone and common sense approach, Maskell shows numbers peo-ple at all levels how that their responsibility during a Lean implementation is not tosimply read the conventional bottom-line profit-and-loss results, but to measureand reflect on the processes influencing that bottom line. He provides the ration-ale, approaches, and tools that will lead to organizations that are flexible andresponsive enough to function optimally in turbulent and unpredictable times. Thebook is updated throughout to reflect recent advances. Notably, it eliminates activ-ity-based costing and management (ABC/M) in favor of the much more expedient value-stream accountingmethods that have been tried and tested in diverse companies over the last ten years.


Target Cost ManagementThe Ladder to Global Survival and SuccessJim Rains

“Target costing is one of the hidden treasures of companies like Toyota andHonda. … We are very fortunate that Jim Rains is bringing this precious informa-tion to us all.


“…a must read for every business executive interested in global success. … arespected world leader in value engineering provides the inspiration and details onhow to incorporate target costing in your organization.”

— Don J. Gerhardt, former Director, Value Engineering, Ingersoll-Rand; and President,Gerhardt Engineering

With a proven track record for helping companies achieve critical cost reductions without sacrificing customersatisfaction or raising prices, target costing provides a way to survive and prosper in today’s increasingly com-petitive market. This book details the preliminary steps required to institutionalize target costing and two nec-essary ingredients: proper organizational structure and cost tables.

Catalog no. K11600, August 2010, 229 pp., ISBN: 978-1-4398-3559-3, $59.95 / £38.99

INDUSTRIES / FUNCTIONS – ACCOUNTING






Innovative Lean DevelopmentHow to Create, Implement and Maintain a Learning CultureUsing Fast Learning CyclesTimothy Schipper and Mark Swets

“While innovation will always be messy business, the authors have eliminatedmuch of the messiness. They have brought systematic thinking to something thatdoes not lend itself to being systematic.“

— Bart Huthwaite, Sr., Huthwaite Innovation Institute

“This is truly a practitioner’s book. … If you follow the standards, you’ll be put-ting Lean development in place, and more important, you’ll be ensuring thebehaviors and practices that sustain it. … there is little mystery involved; these arethings you can teach, expect, observe, and audit.”

— David Mann, author of Creating a Lean Culture

Incorporating Lean and the rules of structured innovation into the development process, this book unleashesthe creativity of all involved in developing new products, services, or processes. Applying this approach, theauthors have helped teams cut development time in half, while delivering award-winning quality solutions.They share those examples while providing a road map that all companies can follow to achieve a Lean devel-opment culture.


Value Stream Mapping for Lean DevelopmentA How-To Guide for Streamlining Time to MarketDrew A. Locher

Written by one of the world’s most respected consultants on Lean, this work pres-ents a methodology for value stream mapping that is appropriate for any organi-zation, whether it be service or product oriented. Over the past 25 years, Locherhas proven just how powerful this process is, having employed it in healthcare,transportation, distribution, education, financial services, and manufacturing envi-ronments. Illustrating his methodology through the example of the imaginaryDevelopTek company, he shows how managers can --

• Identify development waste

• Assess an organization’s current state and develop a Current State Map

• Apply Lean principles to create a Future State Map

• Develop a plan that will help realize that desired future


The Toyota Product Development SystemIntegrating People, Process, and TechnologyJames Morgan and Jeffrey K. Liker

"Absolutely brilliant …. This insightful book finally gives away the secrets ofToyota's Product Development System … read it, and there's no turning back."

— Freddy Balle and Michael Balle, authors of The Gold Mine

"Product Development is one of the key frontiers of Lean thinking …. Learn howto turn the tables on the competition by reading this book."

— Daniel T. Jones, co-author of The Machine that Changed the World

Morgan and Liker compare and contrast the world-class product developmentprocess of Toyota with that of a U.S. competitor. They use extensive examples fromboth competitors to demonstrate value stream mapping as a powerful tool for continuous improvement.Through real examples, they illustrate specific practices, such as multiple function workload leveling, com-pound process variation, effective technology integration, and knowledge management.


INDUSTRIES / FUNCTIONS – PRODUCT DEVELOPMENT






Lean for the Process IndustriesDealing with ComplexityPeter L. King

“… highly recommended.”—Janice M. Gullo, writing in APICS magazine

Drawing on 40 years of experience at one of the world’s largest chemical and mate-rials manufacturers, King provides the first Lean resource written explicitly for theprocess industries. Focusing on where the needs of the process industry differ fromthose of parts assembly manufacturing, he discusses the eight wastes described inLean literature, looking at how they manifest themselves in process operations. Heexplains how to adapt value stream mapping for process operations and how toidentify and eliminate the root causes of bottlenecks.


Creating Mixed Model Value StreamsPractical Lean Techniques for Building to DemandKevin J. Duggan

"… must reading … shows you how to implement a Lean value stream in a waythat everyone will understand."

— Glynn Miller, Director, Consumer Centered Enterprise, Whirlpool,

Duggan goes beyond basic value stream mapping to show how to create futurestates in the real manufacturing world of multiple products, varying cycle times,and changing demand. An attached CD provides spreadsheets to help divide prod-ucts into families and calculate resource needs.


Made-to-Order LeanExcelling in a High-Mix, Low-Volume EnvironmentGreg Lane

"This book is an excellent resource … for those implementing a Lean manufactur-ing system in this environment."

— Lee C. Banks, Senior VP and Operating Officer, Parker Hannifin Corp.

While Lean principles apply in high-mix, low-volume environments, implementa-tion tools must be adapted and alternate methods embraced. Written by GregLane, one of the few individuals certified as a Toyota Production System Key Person,this book is specifically geared for manufacturers that have hundreds to thousandsof active part numbers with few or no ongoing forecasted volumes, and for shopsthat build to order.


INDUSTRIES / FUNCTIONS – JOB SHOP & PROCESS MANUFACTURINGLiquid LeanDeveloping Lean Culture in the Process IndustriesRaymond C. Floyd

“If you truly want world-class performance, you will want a copy of this book onyour desk as a ready reference manual.”

— King Pouw, Executive Vice President, Kellogg Company

One of the first to successfully practice Lean in the chemical industry, Ray Floyddraws on his 20 plus years of experience to show how Lean manufacturing can beapplied to the liquid industries. It includes invaluable information for those involvedwith reactive chemical manufacturing, petroleum and metal refining, and food andbio-pharma production.

Catalog no. PP8629, February 2010, 346 pp., ISBN: 978-1-4200-8862-5, $49.95 / £31.99







Lean Supplier DevelopmentEstablishing Partnerships and True Costs Throughout theSupply ChainChris Harris, Rick Harris, and Chuck Streeter

Offering the same advice that they have successfully applied to corporations acrossthe globe, the authors, award-winning consultants, provide the criteria needed tochoose suppliers that will make good long-term partners, as well as a true costmodel that eliminates guesswork when choosing what suppliers to develop. Theysupply proven PFEP methods to link your facility to the supply base and ways todevelop and maintain information flow all along the supply chain. Real-worldexamples are used to illustrate solutions to likely contingencies. A quarterly suppli-er review is included that you can adapt for your own use.


Lean Culture for the Construction IndustryBuilding Responsible and Committed Project TeamsGary Santorella

Written by a veteran in the construction field, this reference is the first to addressthe direct application of Lean initiatives to that industry. It uniquely addresses peo-ple issues in terms of productivity and waste by applying behavioral psychologyprinciples at a tactical level. The author expands the notion of ethics beyond thesimple litmus test of right and wrong, so team leaders can adopt proper profes-sional and diplomatic attitudes and behaviors toward the implementation of Leanimprovements. An emphasis is placed on flexibility and allowing for contingencies.The author recounts real-world stories to which every construction professionalscan relate.


Implementing Lean Six Sigma throughout theSupply ChainThe Comprehensive and Transparent Case StudyElizabeth A. Cudney and Rodney Kestle

From start to finish, this book details a case study that follows the implementationof a Lean Six Sigma improvement project across a supply chain. Unlike most pub-lished case studies, which give only an overview, this in-depth case presents thedata, and explains in detail how the team drew its conclusions. In addition, theauthors provide a comprehensive glossary of Lean and Six Sigma terminology. Thebook covers use of value stream maps, focus groups, dashboards and scorecards,as well as other methods to identify stakeholder needs, the Voice of the Customer,and areas of waste. Each chapter concludes with exercises. An accompanying CD contains all data usedthroughout the study, so that readers can duplicate the analyses.


INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENTTurbo FlowUsing Plan for Every Part (PFEP) to Charge Your Supply ChainTim Conrad and Robyn Rooks

This book takes PFEP beyond the manufacturing cell to create a tool for managingthe entire supply chain. Written by experts in supply chain integration, this text —

• Discusses internal route planning and design using PFEP data

• Details external logistics and synchronization of manufacturing, logistics, andinventory cycles

• Explains how to manage raw material and WIP inventories using PFEP

• Answers the question How much inventory do I need?








Mastering Purchasing Management for InboundSupply ChainsThomas A. Cook

Many of the lessons about inbound supply – especially foreign purchasing – are farless costly when learned through others’ experience rather than your own. Leavinglittle to chance, international trade expert, Thomas Cook details all the basic fun-damentals of logistics and compliance, while also offering essential insight that evenseasoned supply managers will find valuable. He covers the importance of bondedwarehouses and cost modeling. He presents case studies from a variety of industriesthat illustrate best practices while revealing those things that the savvy tradershould know about foreign trade zones.

Catalog no. PP6197, October 2010, c. 420 pp., ISBN: 978-1-4200-8619-5, $79.95 / £49.99

Kanban for the Supply ChainFundamental Practices for Manufacturing ManagementStephen CimorelliCummins Filtration, Nashville, Tennessee, USA

Written for supply chain managers seeking to improve material flow, this workexplains how to make the conversion from materials requirements planning pushtechniques to the pull techniques intrinsic to kanban replenishment systems. Itshows how to install fundamental kanban concepts that quickly lead to increasedproductivity and profitability. Through an iterative process of planning, adjusting,and executing, dynamic kanban pull techniques keep inventory levels synchronizedwith demand, and keep the supply chain running apace with actual production.

Includes training materials for instructors: communication notes, exercises, and figures


Fix Your Supply ChainHow to Create a Sustainable Lean Improvement RoadmapPaul Husby and Dan Swartwood

“If you value continuous improvement and are looking to gain a better under-standing of complementary methodologies, this is your book.”

— Jerome Hamilton, 3M Director, Lean Six Sigma and Initiatives

Written by business leaders for business leaders, this book explores successful sup-ply chain improvement requirements and methodologies. It covers the use of thesetechniques in a story about Twin City Manufacturing, a fictitious company basedon the authors’ 70 years of combined experience. Whether you are intimately famil-iar with SCM or have limited experience, the authors present a valuable roadmapthat you will be able to immediately apply to supply chain improvement.


INDUSTRIES / FUNCTIONS – SUPPLY CHAIN MANAGEMENT

Compliance in Today's Global Supply ChainThomas A. Cook

Managing director of American River International and a Department of Commerceappointee to the New York District Export Council, Thomas Cook is one of the mostaccomplished experts on international trade. In this comprehensive yet accessibleresource, he provides a step-by-step blueprint for executing a corporate globaltrade program that is both compliant and cost-effective. The text identifies bothtraditional concerns and emerging complications, and then puts forward strategiesto address them. In providing cost-effective solutions for building and securing aglobal supply chain, Cook emphasizes continuing education that will sensitize alllevels of an enterprise to the importance of abiding by changing regulations.

Catalog no. AU6219, October 2010, c. 291 pp., ISBN: 978-1-4200-8621-8, $79.95 / £49.99







The Supply Chain in Manufacturing,Distribution, and TransportationModeling, Optimization, and ApplicationsEdited by

Kenneth D. Lawrence, Ronald K. Klimberg, and Virginia M. Miori

Focusing on research that integrates production, distribution, and transportation,this book provides solutions to significant problems within the supply chain inte-gration process. The text presents both tactical and operational models thataddress a wide variety of organizational issues, including high-level productionschedules, product sourcing, network alignment, distribution center layouts, trans-portation operations with consistent demand, inventory planning, as well as day-to-day operations planning. Leading contributors from industry and academia also provide real-world busi-ness applications and case studies that feature some of the modeling solutions discussed in the chapters.

Catalog no. AU945X, September 2010, 320 pp., ISBN: 978-1-4200-7945-6, $89.95 / £57.99

Introduction to Supply Chain ManagementTechnologiesSecond EditionDavid Frederick Ross

Series: Resource Management

Updated to include the latest advances of Web 2 technologies and their increasinglyubiquitous nature, the new edition of this invaluable resource continues to explorethe concepts, techniques, and vocabulary at the convergence of supply chain man-agement and the Internet. Written by a recognized expert with more than threedecades of SCM experience, it highlights the integrative software toolsets and suitesthat will allow supply chain partners to move to new levels of collaboration, flexi-bility, and overall performance. It covers ways to optimize demand management, manufacturing, and distri-bution functions.

Perhaps most importantly, this book and the technology it champions can help empower executives involved withrestarting a stalled economic environment.


Closed-Loop Supply ChainsNew Developments to Improve the Sustainability of BusinessPracticesEdited by

Mark E. Ferguson and Gilvan C. Souza

Series: Supply Chain Integration Modeling, Optimization and Application

“From the strategic decisions made at the executive suite down to the tactical deci-sions of the production floor, this book offers much insight for any manager inter-ested in adopting a more sustainable business model.”

— John R. Wells, President and CEO, Interface Americas

Written in language that is accessible to practitioners, this authoritative resource examines recent research andcase studies of companies running profitable reuse/remanufacture operations in various industries. It illustratesprofitable practices in returned and recovered products, clearly explaining how to: design a reverse logisticsnetwork, conduct production planning, implement effective marketing strategies, and apply closed-loop sup-ply chain strategies in industries besides manufacturing. From product development to materials to assemblyand profitability, this complete resource explores the impact of these processes across all aspects of the sup-ply chain.

Catalog no. AU9525, April 2010, 257 pp., ISBN: 978-1-4200-9525-8, $79.95 / £49.99







Supply Chain Management at Warp SpeedIntegrating the System from End to EndEli Schragenheim, H William Dettmer, and J. Wayne Patterson

"A must-read business book, not only for supply chain managers, but also forevery decision maker in the company."

— Santiago Cuadra, Director, Information Management, AkzoNobel Paints, Pte. Ltd.

"This book advances Theory of Constraints knowledge for production and distri-bution to a new level. Everyone concerned with supply chain improvement andapplying TOC to these fields should read it."

— Paul Bayer, Quality Manager, BMW Munich

This sequel to the bestselling Manufacturing at Warp Speed refines and updates theformer approach to production management with new ideas that complement earlier tactics. This is the firstbook to describe, in detail, the application of the Theory of Constraints approach to assured availability in dis-tribution, for both original equipment manufacturers and retailers. The authors address the new demandstaken on when a firm accepts rush orders. They also review the issues surrounding availability and the man-agement of inventory moving through distribution systems.


Lean Supply Chain ManagementA Handbook for Strategic ProcurementJeffrey P. Wincel

"Lean supply chain management is a core competency … and if you are seriousabout developing this competency I recommend that you read this book."


Unlike other strategic procurement guides, this handbook considers an organiza-tion's business condition as a contributing factor in the development of a strategicprocurement strategy. That is, rather than taking a one-size fits all approach, theauthor takes a more individualized approach, illustrating techniques specific toorganizations operating in a standard or crisis environment. With methods fordeveloping and tracking strategic procurement initiatives, this book provides purchasers and supplier devel-opment professionals with the tools needed to transform procurement from a mere cost center to a profitgenerator.


Improving the Extended Value StreamLean for the Entire Supply ChainDarren Dolcemascolo

Organized in a workbook format, this volume presents a systematic approach forextending Lean manufacturing across the entire supply chain. The author presentsproven methods for sustaining success and continuously improving the entire sup-ply chain, which should result in increased profits, reduced lead times, lower inven-tory, and better quality. The book includes tips on how to magnify the benefits ofLean on the production floor by extending the Lean principle throughout the enter-prise. Techniques addressed in the book include extended value stream mapping,process kaizen, supplier evaluation, and supplier integration, as they relate to Leansupply chains.

Provides invaluable information for companies deciding what should and should not be outsourced








Mapping the Total Value StreamA Comprehensive Guide for Production and TransactionalProcessesMark A. Nash and Sheila R. Poling

While other books focus on production process value stream mapping or transac-tional process mapping, this work meets the needs of manufacturers and servicesector organizations by detailing both. It teaches readers what techniques are com-monly applicable to any type of organization, and also explains areas of difference,so that map makers will be able to adapt to whatever situations arise. Extending thelessons originally put forward in Value Stream Management for the Lean Office, thishighly practical resource —

• Reinforces fundamental concepts and theoretical models with real-world applications and completeexamples of VSM

• Advances the calculation of process lead time for work queues to cover the very real possibility of hav-ing more work in the queue than available time

• Extends the concept of availability to cover employees as well as equipment


Value Stream Management DVD SetEight Steps to Planning, Mapping andSustaining Lean ImprovementsThis learning package starts with an overview of value streammanagement and the basics of lean. Subsequent lessons willteach you how to map your current state; how to plan and mapyour future state in three stages — demand, flow, and leveling;how to create action plans; and how to develop a storyboardthat communicates the entire process. You will see value streammanagement in action at Wiremold, Mercedes Benz, PellaWindows, and Thetford. Finally, a computer-generated virtualfactory will show how the system comes together and how leanactually works. In addition to the two hour DVD, the package includes a facilitator guide and participant guideand a CD with blank forms and blank map.

Visit the product description at our website for a free demonstration.

Catalog no. PP7338, 2006, DVD (approx 120 min), ISBN: 978-1-56327-338-4, $2099.00 / £1337.00

Value Stream ManagementEight Steps to Planning, Mapping, and Sustaining LeanImprovementsDon Tapping, Tom Luyster, and Tom Shuker

"… exceptional for use in training. … also excellent for busy managers/executiveswho are typically overloaded with material. … You can tell this book is written bypractitioners who have actually done it."

— Bob Angeli, Vice President of Operations, IdraPrince

Value stream management simplifies planning for Lean implementation. It links themetrics and reporting required by management with the tools needed on the man-ufacturing floor. In this volume, the authors stress the importance of reachingbeyond single-point kaizens to ensure a sustainable Lean implementation process. The central feature of thiswork is the value stream management storyboard, a tool representing an eight-step process for Lean imple-mentation. The storyboard brings together people, tools, metrics, and reporting into one visual document.The book is packaged with a CD containing a Lean assessment tool and a storyboard template, as well ascharts, forms, and worksheets.


METHODS & TOOLS – VALUE STREAM MANAGEMENT






The A3 WorkbookUnlock Your Problem-Solving MindDaniel D. Matthews

Facilitating participation and responsibility across an entire organization, this one-of-a-kind workbook takes readers step-by-step through the disciplined develop-ment of an A3 report, a single-sided piece of paper used by Lean industries to pro-mote efficiency. The A3 provides all employees at all levels with a method to quick-ly identify a problem, analyze its root cause, select appropriate countermeasures,and communicate necessary actions to decision makers. The workbook includesworksheet templates that can be reproduced and used in future problem solvingefforts. Just as important as the end result, The A3 encourages an attitude of effi-ciency and a willingness to drill down to the true cause of any sort of waste or inef-ficiency.


The Basics of FMEA2nd EditionRaymond J. Mikulak, Robin McDermott, and Michael Beauregard

Fully updated with enhanced methods to reflect the latest ISO 9000 and ISO/TS16949 standards, this second edition systematically assists developers and engi-neers in achieving quality and cost efficiency. Written by consultants at a highlyrespected engineering firm, this manual fully defines Failure Mode and EffectAnalysis and provides a definitive ten step method for its implementation illustrat-ed by an extended case study. The book demonstrates how to involve all stake-holders in the process so as to identify and preemptively eliminate those productdeficiencies that originate in production. With a long track record of success in themilitary and the automotive industry, FMEA is now being applied to productionconcerns across a variety of industries.

Includes ready-to-use worksheet templates


Basics of Process Mapping2nd EditionRobert Damelio

Since the influential first edition of this bestselling text, many organizations havebecome familiar with systematic improvement approaches such as Six Sigma, Lean,CMMI®, and the Balanced Scorecard, The first step with any of these is to detailprocesses and identify areas of inefficiency. Updated with new chapters and newtools, this volume demonstrates how process mapping can be used to initiate anyimprovement strategy. It shows how to employ the three levels framework, whichallows you to evaluate situations and draw maps for the same work at the organi-zation, process, and job/performer levels. While most texts on mapping focus onmanufacturing, this book concentrates on service and knowledge work.

• Provides new tools to make work processes more clearly visible

• Compares and contrasts process maps with value stream maps

• Includes sample maps and examples that relate to the service and knowledge industries

Catalog no. PP7376, November 2010, c. 192 pp., Soft Cover, ISBN: 978-1-56327-376-6, $15.00 / £9.99

METHODS & TOOLS – PROBLEM SOLVING






Visual ControlsApplying Visual Management to the FactoryChris A. Ortiz and Murry Park

Leaving little room for mistake, this book lays out what might be the most detailedapproach to applying the Lean principles of 5S needed to convert a factory to a fullyfunctional Visual Workplace. The book offers a clear discussion on management'srole in creating a Lean strategy that will implement the visual factory, while alsomolding the workplace culture needed to sustain it. A crucial section of the book isdedicated to discussing how to design and create visual shadow boards, that partof the process where many efforts stumble. It also discusses right-sizing, kanban,and ways to measure performance.


5 Pillars of the Visual WorkplaceHiroyuki Hirano

"… both a groundbreaking book on continuous improvement and a handy guideto the details of creating a superior workplace. Diligently applied, the 5S's willdecrease expenses and boost productivity."

— Jeff Olson, Editor, Soundview Executive Book Summaries

In this pioneering work, Hirano introduces his 5s system, explains why it so impor-tant, and offers guidelines for it nuts and bolts implementation. Filled with numer-ous case studies, graphic illustrations, 40 plus user forms, and training materials, itis a must-have reference for organizations seeking to thrive into a highly competi-tive climate. Addressing the incredulous reaction of executives who deride theprocess for its simplicity, the author warns of disastrous consequences for companies that fail to recognize itsvalue; if they cannot successfully implement 5S, there is little hope of integrating large-scale changes such asJIT or re-engineering.


5S for Operators5 Pillars of the Visual WorkplaceHiroyuki Hirano

Shopfloor Series

"I recommend this book to every supervisor who wants a commonsense, inexpen-sive method for improving quality, productivity, and morale within their depart-ment."

— Jaymie Randel, Training Coordinator, Douglas and Lomason Company

Since its publication, Hiroyuki Hirano’s, 5S for Operators continues to prove itsvalue in one company after another. Hirano’s five pillars of the visual workplace:Sort, Set in Order, Shine, Standardize and Sustain are the most fundamental andoften overlooked aspects in continuous improvement initiatives. Easy-to-read and apply, the book providesguidance for supervisors but can also be used as textbook for on the floor study groups. Each section of thebook is loaded with questions, outlines, summaries, diagrams and illustrations. This book provides the foun-dation that is essential for implementing not just 5S, but overall manufacturing improvements like shorterequipment changeovers, just-in-time inventory, and total quality management and total productive.


See page 8 for other books in the Shopfloor Series

METHODS & TOOLS – 5S







The 5S Pocket GuideJames Peterson and Roland Smith

Written for workers on the floor, this guide is designed to enhance awareness of theprinciples behind the 5S System and identify its impact on improving efficiency andpromoting a safe working environment. Using a condensed format, it outlines a dis-ciplined methodology for implementing 5S, organized around a six-step method.The innumerable benefits of the 5S System include shorter cycle times, increasedfloor space, reduced lead times and training cycles, lowered accident rates,enhanced communication, and less inventory. By employing this handy resource,organizations can more easily build employee awareness of 5S throughout theirplants, leading to dramatic improvements in productivity, safety, and profitability.


5S for Operators Learning PackageHiroyuki Hirano

Thorough, flexible, and almost infinitely customizable, the 5S for Operators Learning Package allows instructors toconduct learning sessions tailored to any organization. Thatcustomizability combined with modules specifically designedto encourage workers to become actively involved in thelearning process makes for a high-impact learning experiencethe workforce won't soon forget.

The 5S for Operators Learning Package contains: Leader'sGuide, 5 copies of 5S for Operators, a CD with additionalpresentation materials, and a copy of the classic 5 Pillars ofthe Visual Workplace. Based on that classic, this packageprovides support in continuous improvement efforts.

Catalog no. PP7124, 1996, Pack, ISBN: 978-1-56327-124-3, $390.00 / £250.00

5S System KitWorkplace Organization and StandardizationPress Productivity and Tel-A-Train

Complete with facilitator and participant guides, the 5S SystemDVD is used to train new employees, launch kaizen events, andlead implementation activities within your workforce. It willteach your employees how to seize control of their workplace,how to own their equipment, and most importantly, how tofoster an environment of continuous improvement on the shopfloor. Covering actual 5S implementation in plants such as Ford,Titleist and Foot-Joy Worldwide, Miller Brewing, ExxonChemicals, Gelman Sciences, and Delco Remy, managers and improvement specialists will see how 5S hasworked for others and how it can work for them. The kit includes a DVD (approx 90 min), Facilitator Guide,and Participant Guide.


Catalog no. PP5837, 1998, DVD (approx. 90 min), ISBN: 978-1-4200-7583-0, $2099.00 / £1167.00

METHODS & TOOLS – 5S






Standardized Work for Noncyclical ProcessesJoseph Niederstadt

Many companies fail to apply rigor to the standardization of noncyclical work,believing that it cannot be measured. This book cuts to the core of that mistakenbelief by showing you how to measure non-repeating job processes and eliminatewaste associated with noncyclical activities and indirect labor assignments throughtheir standardization. Taking a deliberate hands-on approach reflective of his owntime as an operator on the line, Niederstadt lays out the methods that he has insti-tuted in more than 30 factories globally. He covers activities involving multiplemachine job setters, maintenance, stockers, and quality auditors.

Includes a CD with templates of all the forms used, and color versions of images foundin the text

Catalog no. K11219, August 2010, 120 pp., Soft Cover, ISBN: 978-1-4398-2550-1, $39.95 / £25.99

Strategic Error-ProofingAchieving Success Every Time with Smarter FMEAsJohn J. Casey

Developed by manufacturing visionary John Casey, SET defines a logic stream forengineers to strategically incorporate no-cost or low-cost error-proofing devices tohelp production operators. The operators interface with their parts and tools in sucha way that either the product is made correctly, or the process is stopped. Operatorscan make only good parts—nothing else. Succinctly addressing the shop floor real-ities and cultural challenges that can conspire to defeat even the best intentions,this volume —

• Shows how to integrate error-proofing devices into both planning and pro-duction

• Outlines a method to measure the robustness of each operation as well as overall plant efficiency

• Helps you develop a library of standardized methods for solving your most common problems


New Horizons in Standardized WorkTechniques for Manufacturing and Business ProcessImprovementTimothy D. Martin and Jeffrey T. Bell

Understanding the thinking behind standardized work is essential to realizing itsmaximum benefits. This book is an all-inclusive guide to applying standardizedwork principles to virtually any situation or process. It includes an array of examplesthat demonstrate how the concepts can be applied in a variety of industries andbusiness applications. In a step-by-step format, the book discusses the relationshipof the work period of takt time – as expressed in the short-cycle , long-cycle, andnon-cyclic applications – parallel work steps, takt boards, the three main workerinterface levels in job designs, and their applications.


METHODS & TOOLS – MISTAKE-PROOFING






Poka-YokeImproving Product Quality by Preventing DefectsNikkan Kogyo Shimbun

If your goal is zero defects, poka-yoke (mistake-proofing) as a worker tool will helpyou get there. Greater participation by workers can only improve your processes,your products, and your company as a whole. The first section of this book uses asimple, illustrated format to summarize many of the concepts and main features ofpoka-yoke. The second section offers 240 examples of poka-yoke improvementsimplemented in Japanese plants, which can be used as catalysts in study groups.Improvement forms are included that can help capture ideas.


Make No Mistake!An Outcome-Based Approach to Mistake-ProofingC. Martin Hinckley

The centerpiece of Hinckley’s unique mistake-proofing approach is an outcome-based classification system that focuses on preventing rather than detectingdefects. To this end, he offers an amazing encyclopedic compilation of mistake-proofing tools. Based on the irrefutable premise that mistake-proofing is a skill thatimproves through familiarity with previous solutions, Hinckley’s classification sys-tems is designed to help you find outstanding rather than random solutions to cur-rent problems on the shop floor. The book includes mistake-proofing documenta-tion forms that will help you adapt his methodology to your own defect preventionefforts.


Zero Quality ControlSource Inspection and the Poka-Yoke SystemShigeo Shingo

A combination of source inspection and mistake-proofing devices is the onlymethod to get you to zero defects. Shigeo Shingo shows you how this proven sys-tem for reducing errors turns out the highest quality products in the shortest peri-od of time. Shingo provides 112 specific examples of poka-yoke developmentdevices on the shop floor, most of them costing less than $100 to implement. Healso discusses inspection systems, quality control circles, and the function of man-agement with regard to inspection. This classic volume provides a wealth of insightthat is just as valuable today as when it was first published 25 years ago.


METHODS & TOOLS – MISTAKE-PROOFING






A Revolution in ManufacturingThe SMED SystemAndrew P. Dillon and Shigeo Shingo

"One of the most thought provoking manufacturing books anyone can read." — Ken Stork, Past President, AME Target

“Because of Dr. Shingo's direction, we have been able to reduce changeover timefrom 4 to 5 hours to an average of 2.5 to 4 minutes."

— Gifford M. Brown, Plant Manager, Cleveland Engine Plants, Ford Motor Company

From the industrial engineer who developed SMED (single-minute exchange of die)for Toyota, this volume provides a full overview of this powerful just in time pro-duction tool. It offers the most complete and detailed instructions available any-where for transforming a manufacturing environment in ways that will speed up production and make smalllot inventories feasible. The text delves into both the theory and practice of the SMED system, explaining fun-damentals as well as techniques for applying SMED. The critically acclaimed text is supported with hundredsof illustrations and photographs, as well as 12 chapter-length case studies.


Winners Circle DVDPress Productivity

Featuring Indianapolis 500 winners Danny Sullivan and Rick Mears, this highly moti-vational video introduces the quick changeover technique invented in Japan. Thevideo compares the way a racing pit crew functions to a die changeover team in amanufacturing environment. It shows how both must function as a cohesive unitto succeed. It also takes you inside a company that reduced die-changeover fromover two hours to less than five minutes. The video is an excellent way for you tointroduce quick changeover techniques to your employees. It is fast paced andexplains the basic concepts of teamwork in a die-exchange.

Catalog no. PP7633, 2003, DVD (approx 20 min.), ISBN: 978-1-4200-7633-2, $209.95 / £133.00

Kaizen for Quick ChangeoverGoing Beyond SMEDKeisuke Arai and Kenichi Sekine

"Close to the ground, real-life examples of continuous improvement techniquesthat relate to virtually any type of production environment."

— John Gugliotta, V.P. Operations, Lifeline Systems, Inc.

Picking up where Shingo's Single Minute Exchange of Die left off, this book stream-lines the process even further to reduce changeover time, while simultaneously cut-ting staffing requirements in half. The book begins by outlining the tactical princi-ples for improving the three phases of the changeover procedure. Next, it demon-strates how to improve changeover on a processing line. All of the ideas presentedare based on kaizen improvements, which require very little, if any, expenditure. Process razing and the imple-mentation of one-piece flow are also examined as means to eliminate wasteful transportation and searching.


METHODS & TOOLS – QUICK CHANGEOVER






Quick Changeover SimplifiedThe Manager's Guide to Improving Profits with SMEDFletcher Birmingham and James Jelinek

"The SMED program has helped us realize greater manufacturing flexibility in themolding area and all the associated benefits: lower inventory, shorter lead timesand responsiveness to our internal and external customers."

— Linas Biliunas, Director, Manufacturing Operations, Kinetico Inc.

Concise and readily accessible, this critically acclaimed guide is written for compa-nies that need to implement a quick setup and changeover program, but aren'tsure where to start. The authors walk busy readers through basic concepts and theprocess of implementing a mini setup reduction program. They provide quickchangeover tools selected for their ease of implementation. All the examples, including ROI statistics, comefrom real companies that have successfully implemented the strategies and tools discussed. This programoffers a good starting point for those companies wanting to ultimately install a full-scale program.


Quick Changeover for OperatorsLearning PackagePress Productivity

This package provides the foundation for launching a full-scale implementation process that gets all of your workersinvolved. It provides immediate practical skills offered in aflexible curriculum that adapts to your requirements.

Each learning package includes:

• A Leader’s Guide

• 5 copies of Quick Changeover for Operators: TheSMED System

• A CD filled with additional presentation materials

• A copy of A Revolution in Manufacturing: The SMED System, by Shigeo Shingo (page 54)

Catalog no. PP7126, 1996, 174 pp., Pack, ISBN: 978-1-56327-126-7, $390.00 / £250.00

Quick Changeover for OperatorsThe SMED SystemShigeo Shingo

Shopfloor Series

SMED (Single-Minute Exchange of Die) is a method that facilitates equipment orproduct changeovers in record time--often less than 10 minutes. Developed from,A Revolution in Manufacturing: The SMED System and written for managers, thisbook is intended for frontline production and assembly associates. It explains whySMED is important and examines the basic stages of SMED. The authors organizedthe material into chunks of information that can be covered in a series of short ses-sions. Each chapter includes reflection questions to stimulate group discussion.


See page 8 for other books in the Shopfloor Series

METHODS & TOOLS – QUICK CHANGEOVER







Self-Balancing ProcessesTrue Lean Continuous FlowGordon Ghirann

Self-balancing is a simple, elegant solution to line-balancing and a breakthrough in achieving flow. Since thefirst assembly lines of Henry Ford, solutions to line balancing have been cumbersome and have never achievedreal balance or flow. This book provides detailed descriptions of the methods, debugging tools, simulationsoftware, and layouts for achieving true continuous flow in both simple and complex environments. The textoffers solutions to the problems associated with standard line balancing, such as inventory buffers, variation,and operator pace and offers a shortcut for achieving true continuous flow. Various case studies illustrate thereal power that this method has on manufacturing.

Catalog no. K11034, February 2011, c. 200 pp., Soft Cover, ISBN: 978-1-4398-1965-4, $44.95 / £27.99

Cellular ManufacturingOne-Piece Flow for WorkteamsProductivity Development Team

Shopfloor Series

Straightforward and free of frill, this workbook introduces production teams tobasic cellular manufacturing and teamwork concepts and orients them for partici-pating in the design of a new production cell. Use this book to get everyone onboard to reduce lead time, work-in-process inventory, and other profit-drainingwastes. Each chapter includes an overview and a summary to reinforce concepts, aswell as reflection questions, which can be used to encourage group discussions.This volume is part of the Productivity Press Shopfloor Series, which offers a simple,cost-effective approaches for building basic knowledge about key manufacturing improvement topics


Reorganizing the FactoryCompeting Through Cellular ManufacturingNancy Hyer amd Urban Wemmerlov

"… a great handbook for a manager either just starting to investigate cells orsomeone experienced with cells and looking to upgrade ... . It also addresses …setting up office cells. Many companies don't realize the large potential benefits ofgoing cellular in the office as well as on the manufacturing floor.”

— Ronald Leong, Manager, Delphi Automotive Systems

This Shingo Prize recipient presents a thoroughly researched and comprehensivelife-cycle approach to cellular work organizations. It takes you from the basic cellconcept and its benefits through the process of justifying, designing, implement-ing, operating, and improving this new type of work organization in offices and on the factory floor. The bookdiscusses many important technical dimensions, such as factory analysis, cell design, planning and control sys-tems, and principles for lead time and inventory reduction. It also covers managerial issues that arise whenorganizing work into cells.


METHODS & TOOLS – CELLULAR MANUFACTURING






Custom KanbanDesigning the System to Meet the Needs of Your EnvironmentRaymond S. Louis

"This is the first kanban book I have read which clearly understands that there isa significant difference between environments. … highly innovative, insightful,and clearly written by an author who has years of implementation experience."

— Terry O'Neill, Vice President, Operations, CMS Products

"Exceptionally comprehensive and detailed … provides detailed action plans forimplementation in multiple environments."

— Henry M. Lee, Manager, Operations, Gulf States Toyota

Raymond Louis demonstrates how to develop and implement a successful kanbansystem by selecting appropriate techniques based on the environmental factors and needs of specific organi-zations. The book fully explains each technique, including a description of the environment and type of com-pany it is intended to serve. In all, the author explains more than 20 design options and associated replenish-ment techniques, so that most every reader will be able to custom develop his or her own kanban system. Thisis the only text that thoroughly deals with both the design and implementation of a complete kanban system.


Kanban for the Shopfloor LearningPackageProductivity Press Development Team

A complete and flexible curriculum for teaching kanban andmaking it part of your company’s culture and mode of oper-ation, the learning package shows the difference betweenkanban and conventional ordering systems.

The kanban learning package includes the following:

• Leader’s Guide

• 5 copies of Kanban for the Shopfloor

• 1 laminated job aid: A Kanban Implementation Summary

• 1 copy of the classic book Kanban: Just-in-Time At Toyota

• Additional presentation materials on CD

Catalog no. PP7284, 2004, Pack, ISBN: 978-1-56327-284-4, $390.00 / £250.00

Kanban Just-in Time at ToyotaManagement Begins at the WorkplaceJapan Management Association

Toyota’s world-renowned success proves that Just-in-Time (JIT) makes other manu-facturing practices obsolete. This simple but powerful book is based on the semi-nars given by Taiichi Ohno and other senior production staff to introduce Toyota’sown supplier companies to JIT. It teaches the philosophy and implementation ofwhat many call the most efficient production system in the world.

Real and typical results at American companies after reading this book:

• Lead-time on one product was reduced from 12 weeks to 4 days

• Setup time on a large blanking press was reduced from eight hours to one minute and four seconds

• Work-in-process reduced 50 percent plant-wide

• Factory floor space opened up 30 to 40 percent


METHODS & TOOLS – KANBAN






Corporate SigmaOptimizing the Health of Your Company with Systems ThinkingAnwar El-Homsi and Jeff L. Slutsky

“… the clearest, simplest and most practical book I have ever read on this sub-ject.”

— Stephen G. Haines, founder and CEO of Haines Centre for Strategic Management

Proposing that corporations, like human bodies, have vital systems that must becared for, this book outlines how to monitor these vital organs in a corporation. Itprovides a roadmap for leaders to plot a course from where they are now, to wherethey want to be. It begins by describing how leaders formulate effective organiza-tional vision, mission and values, how to foster and nurture shared organizationalvision to succeed, and how to clearly define strategic balanced business objectives. The book identifies thefunction of organizational departments and shows how to assess the quality level or health of these depart-ments using both Lean and Six Sigma improvement tools.


RSM SimplifiedOptimizing Processes Using Response Surface Methods forDesign of ExperimentsPatrick J. Whitcomb and Mark J. Anderson

"… a thorough but succinct overview of response surface methods. It equipstypical engineers or industrial scientists with all that they will need to startusing these powerful optimization techniques… ."

— John D. Guerin, President, Turning Points Management Consulting, Inc.

A complete demystification of response surface methods (RSM), this book takesa simple-and-fun approach that provides knowledge on RSM in an easy infor-mal style. Keeping formulas to a minimum and making liberal use of figures,charts, graphs, and checklists, the book offers relevant examples, amusing sidebars, and do-it-yourself exer-cises that lead readers to the peak potential for their product quality and process efficiency. The book includesa 180-day trial for Stat-Ease's newest software: Design-Ease®,v. 7, which allows readers to do complex statis-tical computations, generate graphics, and perform numerical optimization.


DOE SimplifiedPractical Tools for Effective Experimentation, Second EditionMark J. Anderson and Patrick J. Whitcomb

"By taking situations from everyday life and using simple language to transferthem to manufacturing and laboratory environments, the authors have madean often dry, difficult subject attainable for the uninitiated."

— Jay Yongless, Assistant Editor, Quality in Manufacturing

Offering a planned approach for determining cause and effect, this work pro-vides researchers with the statistical means to analyze how numerous variablesinteract. With this second edition, Anderson and Whitcomb retain their livelyapproach to the learning of fundamentals, lightening up the text with interest-ing sidebars and amusing anecdotes. They offer a four-step planning process fordesigning and executing experiments. Accompanying the book is a 180-day trial for Stat-Ease's newest soft-ware: Design-Ease®,v. 7, which assists with mathematic computations, allowing one to focus on data analysis.


METHODS & TOOLS – SIX SIGMA / STATISTICS






Using Lean for Faster Six Sigma ResultsA Synchronized ApproachMark Nash, Sheila R. Poling, and Sophronia Ward

"Those who are interested in getting past all the theory and want to get on tomaking money must read this no-nonsense book."

— Skip Steward, Plant Operations Manager, Emerson

"An absolute 'must read' for those embarking on the Lean Six Sigma journey andan excellent resource guide for those who already have."

— Mick Chomyn, General Manager & Lean Project Coordinator, Path Links PathologyServices

Amidst the plethora of resources on merging Lean and Six Sigma, this book detailsa logical alternative: a no-nonsense strategy for maintaining the best of both without diluting either. Theauthors lay out the differences between Lean and Six Sigma, define the power and focus of each, and detailwhy and how to use them in a synchronized complementary way. This practical, easy read shows how to pickthe right projects, people, and toolsets to achieve bottom-line results faster. Readers will benefit from theauthors' years of experience implementing Lean with Six Sigma, through detailed case studies from both man-ufacturing and service companies.


Six Sigma Tool NavigatorThe Master Guide for TeamsWalter J. Michalski

Michalski provides a complete compendium of actual tools, definitions,and techniques needed to move your organization closer to producingminimal defects. It includes a collection of Six Sigma tool strings that allowteams to combine Six Sigma tools to accomplish a particular outcome. Thebook classifies each tool by process application, description of variousapplications, possible links to before and after tools, and problem-solvingphases most applicable for the tool. In includes —

• A comprehensive overview of 222 improvement tools coveringbenchmarking, cause and effect, control, FMEA, and process mapping

• Over 70 tool string flow charts

• A Six Sigma tools cross reference section

• Comprehensive statistical tables

• A CD-ROM containing a searchable version of the entire text


Six Sigma FundamentalsA Complete Introduction to the System, Methods, and ToolsD.H. Stamatis

“...a single, straightforward reference book, Six Sigma Fundamentals answersthe Quality call all by itself. … If you can only have one book...this is it, notonly for Six Sigma Green and Blackbelts, but also for anyone involved in thefield of Quality.”

— Janet MacDonald, Chair, American Society for Quality

With a focus on both manufacturing as well as non-manufacturing organiza-tions, this book demystifies the Six Sigma methodology and provides the read-er with a solid understanding of what defines a Six Sigma initiative. Each chap-ter fully addresses the concepts of the Six Sigma philosophy and explains themethodologies for real-world applications.


METHODS & TOOLS – SIX SIGMA / STATISTICS






The OEE PrimerUnderstanding Overall Equipment Effectiveness, Reliability, andMaintainabilityD.H. Stamatis

Assessing existing and new equipment from classical, reliability, and maintainabili-ty perspectives, this primer explores the overall effectiveness of machines andunveils novel methods that focus on design improvement—including hazard analy-sis, rate of change of failure (ROCOF) analysis, failure rate finite element analysis(FEA), and theory of inventive problem solving (TRIZ). It covers loss of effectiveness,electrical maintenance, Weibull distribution, measurement techniques, andmechanical and electrical reliability. The book also discusses Reliability andMaintainability (R&M), not as tools to be used in specific tasks, but as a discipline.It also considers the application of OEE as an overall improvement tool

Includes a bonus CD with more than 100 pages of appendices and additional resources featuring statistical tables,outlines, case studies, guidelines, and standards

Catalog no. K10723, June 2010, 502 pp., Soft Cover, ISBN: 978-1-4398-1406-2, $54.95 / £38.99

TPM in Process IndustriesTokutaro Suzuki

Process industries have a particularly urgent need for collaborative equipment man-agement systems, but until now have lacked for programs directed toward theirspecific needs. TPM in Process lndustries brings together top consultants from theJapan Institute of Plant Maintenance to modify the original TPM DevelopmentProgram. In this volume, they demonstrate how to analyze process environmentsand equipment issues including process loss structure and calculation, autonomousmaintenance, equipment and process improvement, and quality maintenance. Forall organizations managing large equipment, facing low operator/machine ratios,or implementing extensive improvement, this text is an invaluable resource.


UptimeStrategies for Excellence in Maintenance Management, SecondEditionJohn Dixon Campbell and James Reyes-Picknell

"This is a significant and very welcome upgrade to what was already an impor-tant standard text. It should be required reading for all maintenance managersand those senior executives who want to understand the contribution of physicalasset management to their business success."

— Ben Stevens, President, OMDEC Inc.

In today's competitive marketplace, the flow of goods must not be hindered byavoidable obstacles such as maintenance downtime. This book provides insight intosuccessful strategies for managers, maintenance, and non-maintenance professionals alike. It covers currenttrends in technology, reliability maintenance improvements, and the challenges of finding qualified mainte-nance personnel due to an aging labor force. In addition, it gives a thorough review of what it takes to achieveexcellence in maintenance. In treating this technical topic, it links a variety of seemingly disparate and com-peting concepts into a single simple strategy.


METHODS & TOOLS – TOTAL PRODUCTIVE MAINTENANCE






Autonomous Maintenance DVD SetShopfloor TPM ImplementationProductivity Press

With Productivity's Autonomous Maintenance training, you'll learn how to unleashthe hidden potential on your shopfloor and dramatically lower your productioncosts. The video takes you inside American companies that have successfully intro-duced autonomous maintenance. You hear managers, shopfloor maintenanceworkers and team leaders describing how it worked for them. Employees from bothdiscrete manufacturing and the process industry share their methods and success-es in implementing autonomous maintenance. Involving all your employees inmaintenance activities will benefit your company, because the people who operatethe machines on a daily basis understand the finer details of a machine's function-ality. They can spot early signs of problems and save your company money by preventing costly repairs andlong delays in the production process. In addition to the two hour DVD, the package includes a facilitatorguide and participant guide.


Catalog no. PP7337, 2006, DVD (approx. 120 min.), ISBN: 978-1-56327-337-7, $2099.00 / £1337.00

Autonomous Maintenance in Seven StepsImplementing TPM on the Shop FloorFumio Gotoh and Masaji Tajiri

Illustrated with examples from Toyota, Asai Glass, Bridgestone, Hitachi, and othertop companies, this book comprehensively covers all seven steps of autonomousmaintenance (AM). It provides an overview of AM features and checklists for stepaudits to certify team achievement at each step. The author discusses TotalProductive Maintenance (TPM) basics such as the six big losses, overall equipmenteffectiveness (OEE), causes of losses, and six major TPM activities. He includes animplementation plan for TPM and five countermeasures for achieving zero break-downs, useful guidelines and case studies in applying AM to manual work such asassembly, inspection, and material handling.


Practical TPMSuccessful Equipment Management at Agilent TechnologiesJames Leflar

Replete with annotated photographs and illustrations documenting Agilent's suc-cessful program, this book offers an invaluable roadmap to TPM implementation.Drawing on his experience at Agilent, the author explains the fundamental con-cepts of TPM, including the six basic principles, goals, cultural changes that resultfrom TPM, and keys to successful implementation. He describes, in step-by-stepdetail, the evolution of Agilent’s TPM program, clearly defining and demonstratingeach phase. The book focuses on developing a vision and a strategy for successfulTPM programs. It includes master checklists, forms, and appendices with examplesof maintenance training materials.


METHODS & TOOLS – TOTAL PRODUCTIVE MAINTENANCE






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For those who are tired of just talking about health care reform

Adopting the principles and practices of the ToyotaProduction System, VirginiaMason has moved fromthe red into the blackwhile improving onall measures ofpatient care.

While the journey is not an easy one, it is possible for any medical facility to transition itself to one that delivers superb medical care while at the same timecontrolling costs. And more and more are coming to Virginia Mason to find out how…

At the newly improved Virginia Mason Medical Center:

See pag

e 22

• Nurses now spend 90 percent of their time in direct patient care

• Liability insurance costs have dropped by over a third

• Rates of central line infections, injurious falls, and surgical site infections arenow some of the lowest found anywhere

• Profits are strong enough that all staff receive bonuses



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their HR departments.

See page 33.



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