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How To Implement Lean Manufacturing [Hardcover]

Lonnie Wilson
5.0 out of 5 stars  See all reviews (3 customer reviews)
Price: 33.99 & FREE Delivery in the UK. Details
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Book Description

1 Sep 2009 0071625070 978-0071625074

A Practical, Hands-on Guide to Lean Manufacturing

This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made.

How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to:

  • Rigorously test and retest the state of your "leanness" with unique evaluators
  • Develop and deploy plant-wide strategies and goals
  • Improve speed and quality and dramatically reduce costs
  • Reduce variation in the manufacturing system in order to reduce inventory
  • Reduce lead times to enable improved responsiveness and flexibility
  • Synchronize production and supply to the customer
  • Create flow and establish pull-demand systems
  • Perform system-wide and specific value-stream evaluations
  • Generate a comprehensive list of highly focused Kaizen activities
  • Sustain process gains
  • Manage constraints and reduce bottlenecks
  • Implement cellular manufacturing

Frequently Bought Together

How To Implement Lean Manufacturing + The Lean Six Sigma Pocket Toolbook: A Quick Reference Guide to 70 Tools for Improving Quality and Speed
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Product details

  • Hardcover: 336 pages
  • Publisher: McGraw-Hill Professional (1 Sep 2009)
  • Language: English
  • ISBN-10: 0071625070
  • ISBN-13: 978-0071625074
  • Product Dimensions: 23.6 x 19.3 x 2.8 cm
  • Average Customer Review: 5.0 out of 5 stars  See all reviews (3 customer reviews)
  • Amazon Bestsellers Rank: 120,549 in Books (See Top 100 in Books)
  • See Complete Table of Contents

More About the Author

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Product Description

About the Author

Lonnie Wilson has been teaching and implementing Lean techniques for over 39 years. His experience spans 20 years with an international oil company where he held a number of management positions. Then in 1990 he founded Quality Consultants which teaches and applies Lean techniques to not only small entrepreneurs but also Fortune 500 firms, principally in the United States, Mexico and Canada.

Inside This Book (Learn More)
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Customer Reviews

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Most Helpful Customer Reviews
6 of 6 people found the following review helpful
5.0 out of 5 stars Clear guide to lean manufacturing 5 July 2010
By Rolf Dobelli TOP 500 REVIEWER
Lonnie Wilson brings decades of experience to this practical guide. He shows you how to put lean manufacturing to work in the real world without the usual windbag textbook theories and with plentiful examples. getAbstract finds that he provides solid information about what you need to do (and don't need to do) to maximize lean's benefits for your company. Wilson is clear and strikingly passionate. His manual is not difficult to understand, but it is somewhat technical. He directs his lessons - and his informed opinions - toward those who already know a good bit about manufacturing processes. He explains how Toyota uses lean within its Toyota Production System, but he also discusses how you can put lean into practice. Wilson describes how important corporate culture is to implementing lean manufacturing and notes which aspects of your organization must align with its approach. The book is full of checklists, assessments and charts to help you get to its core principles easily and grasp them quickly without ever getting lost in a fog of philosophy.
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5.0 out of 5 stars Judge this book by its cover 2 Jun 2014
Format:Hardcover|Verified Purchase
This book does exactly what it says. If you want to implement lean in an organisation that has never used it before then this is the book to get. It starts off with ways of assessing the companies ability to be successful and then deals into the detail of implimentation.
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5.0 out of 5 stars another good read 25 July 2013
Format:Hardcover|Verified Purchase
if you want to learn about lean manufacturing this is not a bad place to start.

If you have heard of lean manufacturing and know some of the jargon and want to understand more Mr Wilson's book can help.

this book teaches you how to start in lean manufacturing and where to look for more information to continue the journey.

you realise lean is not a quick fix but a way of life.

the book helps you find your way and what suits your style and method of learning.

Reading the book is just the start, you need to be committed to succeed at lean manufacturing.

Lean is not the stuff of genius but of steady long term effort and commitment, thats my reading Mr Wilson's message.
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Most Helpful Customer Reviews on (beta) 4.9 out of 5 stars  23 reviews
19 of 20 people found the following review helpful
5.0 out of 5 stars Recommended to Those Wanting to Apply Lean Techniques 31 Aug 2009
By RKooiman - Published on
An industrial contractor once told me that he really liked the fact that companies were trying to apply Lean because he got a lot of work as a fallout of poor application.

It's amazing to me that companies will try to adopt state-of-the-art manufacturing concepts, such as Lean, without a good understanding of what they hope to accomplish or even why the concepts have become popular.

I think part of the reason is that there is not much useful, practical advice on how to do it.

This book goes a long way toward filling that void.

It is loaded with practical examples and exercises to clarify the application methods and benefits. It has some suggestions on getting started that can make you money almost immediately.

Chapters 2-5 provide a good overview (and there is a glossary for quick reference). Chapters 6-8 give a step-by-step procedure for getting started. Other chapters explain how to advance a process already in place and several chapters have excellent case examples. I especially liked chapter 18 where there is a simple experiment with dice to show the effect of variation on plant capacity.

I very much enjoyed reading this book because it helped me understand the principles and how to apply them. I was also impressed with how much the case studies reinforced the principles and tied them to real events. I recommend it to those who wish to implement lean in their facility.
10 of 10 people found the following review helpful
5.0 out of 5 stars Outstanding Practical Guide to Lean Manufacturing! 23 Sep 2009
By William D. Buck - Published on
If you have read "LEAN THINKING" by James P Womack and Daniel T. Jones, you may have been left wondering what Lean Manufacturing and the Toyota Production System was all about. It may have seemed mysterious and not well defined. Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING" is a guidebook to Lean Manufacturing that will take the mystery out of process for you. It is a practical HOW-TO guide that can be used by plant managers, executives, quality managers and production personnel to implement the Lean Systems within their facilities.

This book not only addresses the strategy on how to implement Lean Manufacturing but also addresses cultural change necessary for a successful transformation. In the end you have to sustain the gain and the book tells you what is necessary.

What makes this book standout from other Lean texts is that the book itself is written in a Lean style of writing. Lonnie uses "Points of Clarity" to highlight important concepts within the book. Additionally he uses hundreds of visual graphics and tables that draw the reader's attention. Visual clues and organization is a key concept in Lean. I don't think you can turn two or more pages without being grabbed by a new visual to help make a point in the book.

I was impressed with the level of practical detail. Need to calculate OEE or the proper KANBAN size? Does Value Stream Mapping have you confused? The book provides the formula's necessary. It places these concepts in context to the big picture of efficiency, lead-time or cycle-time reduction. The book is filled with personal examples from Lonnie Wilson's career leading transformation efforts. Case studies are also given to drive home and follow the complete process of a successful Lean project and some that are not so successful.

This is a book I would personally recommend to anyone getting ready to attend a Lean training workshop. Read this book first and you will be prepared for your class. As a university instructor, I like to tell my students, "The answer is in the book". I think you will find many insightful answers about Lean in Lonnie Wilson's "HOW TO IMPLEMENT LEAN MANUFACTURING".
7 of 7 people found the following review helpful
5.0 out of 5 stars A practical approach to implementing lean manufacturing 20 Dec 2009
By Craig Matteson - Published on
Lonnie Wilson teaches you how to implement the best aspects of lean manufacturing without having to implement the cultural aspects of the Toyota Production System. He believes that cultural transformation, while a benefit if you can pull it off, keeps you from realizing he benefits of Lean quickly, is risky, and adds cost to your Lean project.

Chapter 1 explains his views along these lines and Chapter 2 is a look at Toyota's System and why you need a manufacturing system that focuses on behavior more than culture. Chapter 3 shows you why variation gets in the way of your manufacturing goals and how inventory masks and is the result of variation. You want to eliminate inventory and you have to eliminate variation in order to eliminate the need for inventory. Chapter 5 shows you why Lead Time exists and how you can reduce it.

Chapter 6 discuses the basics of Cultural Change and how need to start thinking about Lean and your manufacturing culture. Chapter 7 looks at strategic approaches you can take to becoming a Lean Manufacturing environment and shows you what Takt is and how to use it. You also get a look at what a basic time study is and how to conduct a balancing study. Spaghetti Diagrams and Value Stream Mapping are also discussed.

Chapter 8 takes you through a Lean implementation process while chapter 9 looks at how to do Lean planning and how to set appropriate and achievable goals. Chapter 10 shows you how to maintain the gains you worked so hard to make and chapter 11 looks at the effect of your culture on Lean and how to think about what you can do with your own.

Chapters 12 and 13 deal with managing your constraints and the benefits you can realize by using cellular manufacturing. Chapter 14 is a case study on cultural change and chapter 15 is a case study on early gains realized by reducing lead times. Chapter 16 is three small case studies as good examples of what to do. Chapter 17 looks at what happens when Lean is used poorly. The last three chapters show you how to conduct your own experiments on variation and inventory, a bunch of assessment tools you can use, and a summary of how your company can become a house of Lean.

This is, I believe, a useful and practical book. Heaven knows, we need to become even more competitive to hold onto as many manufacturing jobs as we can. Maybe someday we can once again grow our manufacturing base. But if we ever do, it will be because we have become globally competitive not because of some series of spending initiatives out of Washington D.C..

Reviewed by Craig Matteson, Ann Arbor, MI
4 of 4 people found the following review helpful
4.0 out of 5 stars A solid and practical introduction 25 Jun 2012
By Otter - Published on
As the author of Manufacturing for the Real Bottom Line and someone who's been in manufacturing for most of his adult life (managing production for parts used in cars made by Toyota, Honda and other automotive companies) I thought this book brought a practical side to Lean not seen in too many other books. It's clear and most of the tools are represented properly with steps for implementation.

The writing style may not appeal to everyone, but if doesn't try to get past that and aborb the information. All in all, a solid book on Lean and one that I would recommend.

David Ottenstein
5 of 6 people found the following review helpful
5.0 out of 5 stars A how to manual to Lean Manufacturing in the real world 15 Sep 2009
By Robert Simonis - Published on
The Japanese word "sensei" is usually translated into English as "teacher" but the literal translation, and possible better translation for this purpose, is "one that has gone before".

Lonnie Wilson's practical and pragmatic new book "How To Implement Lean Manufacturing" shows why Lonnie deserves the title "sensei". Lonnie shows us the way, and the potholes, because he has gone this way before, many times.

Mixing lean, theory of constraints, and six sigma (aka variation reduction), Lonnie shows how to move companies forward towards a better business model and greater profits. His writing style is personal and direct which makes the book easy to read in addition to causing deep thought about our own experience, leadership, and business situation. Lonnie does not lecture on about theory but shows practical applications and examples of how to use the Toyota Production System and Lean Manufacturing in our companies here and now.

After reading this book cover-to-cover I will keep it handy for reference and to have colleages read sections and discuss. I think everyone that is engaged in implementing Lean, or considering implementing Lean, should read this book.
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