Becoming Lean: Inside Stories of U.S. Manufacturers

Book Description
The lean revolution is here. And while you may understand that this revolution is a profound shift away from the traditions of mass production, the concept still causes many people to scratch their head and ask, "what exactly is lean manufacturing?" Lean is much more than techniques. It is a way of thinking-a whole-systems approach that creates a culture in which everyone in the organization continuously improves their process and production. Yet even for those organizations that have come to understand the power of lean, it may be a lost opportunity if they lack the knowledge to implement its powerful concepts. Or, receiving only a piece of the puzzle, they end up falling far short of lean's potential benefits. Not surprisingly, implementing lean manufacturing has proved a challenge for many U.S. companies. But organizations have succeeded, and now you have a unique opportunity to benefit from their experience. In Becoming Lean, Jeffrey Liker has compiled a collection of stories from today's manufacturers already on the front line of the lean revolution. Here is the first book to go beyond descriptions of lean management to include powerful first-hand accounts of the complete process of change, its impact on the entire organization, and the rewards and benefits of becoming lean. Twelve American manufacturing companies tell their stories of successfully implementing lean methods. In their own words, the authors offer personalized accounts of their organization's lean transformation-including struggles, successes, and surprises. Many of the executives and managers who led the charge to lean in their own organizations tell their stories here for the first time. Some of the companies you'll read about include General Motors, Freudenberg-NOK, Gelman Sciences, Western Geophysical Exploration Products, Garden State Tanning, Donnely Corporation, and Cedarworks. The accounts provide not only a realistic view of what it takes to get lean, but evidence of the performance benefits of lean production systems.


From the Back Cover
Excerpts from Becoming Lean: "Becoming Lean fills an urgent need by describing in great detail the initial steps taken by a number of pioneering American firms in a range of industries to introduce lean thinking. Change agents actually leading the effort describe precisely what worked and what didn't.... Your job is to study their examples and advice carefully, and to look in the mirror to see if you are the change agent who will make the future better than the past." -From the foreword by James P. Womack Author of The Machine That Changed the World "Lean systems are the best competitive tool available in business today. ... Our savings on everything from productivity and cycle time to travel distance and work-in-process inventory have been dramatic. ... Tapping the workers' knowledge and creativity through lean systems at Freudenberg-NOK has been the most powerful resource our company has ever known." -Joseph C. Day, CEO Freudenberg-NOK "The concept of lean is disarmingly simple to understand, but bringing yourself to apply it is difficult. To really believe in the key principles of lean you must consistently apply lean-day after day, month after month. Only then, after years of daily hands-on dedication, will you achieve the performance levels possible with lean production." -George Koenigsaecker, President The HON Company "One of the primary reasons for the remarkable improvements in quality and productivity that were achieved at Plant 6 is that Delphi tapped into the potential of every employee to establish a working environment-one in which everyone can help in running the business. To unleash the power of the work force and implement real change, management, union leaders, and the work force must move together toward a common vision." -Daniel Woolson and Michael A. Husar on Delphi Saginaw Steering Systems, General Motors


About the Author
Jeffrey K. Liker is associate professor of industrial and operations engineering and co-founder of the Japan Technology Management Program at The University of Michigan, Ann Arbor. Dr. Liker has received three Shingo Prizes for Excellence in Manufacturing Research. He has actively consulted on innovative manufacturing methods for companies such as Whirlpool, Chrysler, Ford, Renault, and Peugeot.


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This volume, touting Lean Production, provides an explanation of the philosophy itself and compiles stories, recounted by the CEOs, consultants, and plant managers, from a variety of successful manufacturing companies that have implemented Lean Production. Annotation c. by Book News, Inc., Portland, Or.


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