THE TOYOTA KAIZEN CONTINUUM: A PRACTICAL GUIDE TO IMPLEMENTING LEAN STEWART J. Księgarnia

Written by a recognized leader in the manufacturing industry with nearly two decades of experience working for Toyota, this book supplies a firsthand account of the realities behind implementing the Toyota Production System (TPS).

The Toyota Kaizen Continuum: A Practical Guide to Implementing Lean presents authoritative insight on how to use the TPS to drive operational value and improvement across all segments of an organization.

Highlighting valuable lessons learned directly from the TPS masters at the Toyota factories in Japan, John Stewart provides a time-tested approach for implementing a process of continuous improvement. Delving into his wide-ranging experience—that includes time as a team member on the assembly line and managing the vehicle assembly division for Toyota’s largest European operation in the United Kingdom—he explains how to get the process started, how to get senior management excited about the possibilities, and details a process for implementing the TPS in your organization.

Written by an industry veteran named one of the Top 10 Automotive Executives by Automotive News in 2007
Unveils the methods used within the walls of the world’s premier manufacturing organization
Illustrates valuable lessons learned with real-world examples of TPS implementations
Describes five simple steps for executing change in any organization

The book includes case studies that illustrate real-life successes and failures behind the walls of the world’s largest automobile manufacturing organization. Detailing a five-step process for executing improvement initiatives, it supplies you with the tools and understanding of the core principles of the TPS needed to implement and sustain a culture of continuous improvement in your organization.

John Stewart is an operating partner with the private equity firm Monomoy Capital Partners in New York. Mr. Stewart's professional experience includes 18 years with Toyota Motor Corporation in various operational and executive positions. During his time with Toyota, he worked his way from working as a Team Member on the Assembly line to managing the Vehicle Assembly Division for Toyota’s largest European operation in the United Kingdom.

Mr. Stewart was recognized within Toyota as being an expert at utilizing the Toyota Production System to effect change in various environments. He was often selected for some of the toughest assignments in Toyota, culminating in the turnaround of the operations in the United Kingdom. He spent over 88 weeks in Japan with Toyota. During this time, Mr. Stewart was trained by some of Toyota’s most talented Japanese masters on all things relating to the Toyota Production System. Mr. Stewart is a recognized leader in the automotive and manufacturing industry and is frequently sought after to serve as a Sr. Advisor to manufacturers across the globe. He was named one of the top 10 automotive executives by Automotive News in 2007.

Table of Contents

Introduction
Don’t Believe Everything That You Read in a Book ABC’s of TPS The Kaizen Continuum

Foundational Elements of the Toyota Production System
An Overview of the Toyota Production System Toyota’s Recent Turmoil A History of the Toyota Production System Kentucky Alchemy Keep It Simple The Toyota Production System versus Lean Manufacturing Standardization Quest for the Cube Visiting the Plant Floor Understanding Standardized Work Just In Time (JIT)
The Pull System Flow Production Takt Time Jidoka Continuous Improvement (Kaizen)
Developing the Tools

Why the Toyota Production System Makes Sense: Common Sense
Common Sense 101
Understanding Value Understanding Demand Common Sense in Action

Common Misconceptions and Misunderstandings Regarding the Toyota Production System
TPS Misconceptions and Misunderstandings Which Way Is Best?
Toyota Production System Historical Overview Kanban System Overview The Toyota Way The Customer Knows Best Go. See. Act

Waste Management … Improving the Manufacturing Process One Kaizen at a Time
Gap Management The Three M’s Muda Transportation Waiting Overstock Overproduction Repair Overprocessing Non-Value-Added Work Muri Mura Classification of Muda Transportation Waiting Overstock Overproduction Repair Overprocessing Non-Value-Added Work Muda Countermeasure Methods Waste Elimination Example

The Golden Rules of the Toyota Production System
Fundamentals The Golden Rules of TPS Simplify Standardize Specialize Capital Investment Guidelines Tangible Return on Investment Period Recycle, Redeploy, and Reuse Simple, Safe, and Reliable

Cost Management for Profitability
Understanding the Death Spiral Understanding the Cost Structure Fixed and Variable Costs Minimum Variable Costs Break-Even Point Managing Costs Managing Cost Example

Execution
Facing Reality The Five-Step Process for Executing Improvement Initiatives Assessment: Understanding the Business Setting the Course Identify the Project Leader Completely Understand the Project Assessment Completely Understand the Project Target Identify the Project Resources Determine the Roles and Responsibilities Develop the Plan Completely Understand the Costs Communicate Execution Rapid Implementation Stabilization Continuous Improvement Conclusion

Index

218 pages, Hardcover

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