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Becoming Lean: Inside Stories of U.S. Manufacturers
Author: Jeffrey Liker
Product Code: 1737
ISBN: 1-56327-173-7
Publisher: Productivity Press
Published: 1997
Pages: 517
Binding: Hard Cover
Dimensions: 6.25" X 9.25" X 1.25"
Illustrated: Yes
Price: US $40.00

What is Lean?
Pure and simple, lean is reducing the time from customer order to manufacturing by eliminating non-value-added waste in the production stream. The ideal of a lean system is one-piece flow, because a lean manufacturer is continuously improving.
Most other books on lean management focus on technical methods and offer a picture of how a lean system should look like. Other books provide snapshots of companies before and after lean was implemented.

This is the first book to provide technical descriptions of successful solutions and performance improvements. It's also the first book to go beyond snapshots and includes powerful first-hand accounts of the complete process of change; its impact on the entire organization; and the rewards and benefits of becoming lean.

At the heart of Becoming Lean are the stories of American manufacturers that have successfully implemented lean methods. The writers offer personalized accounts of their organization's lean transformation. You have a unique opportunity to go inside the implementation process and see what worked, what didn't, and why.

Table of Contents

1. Introduction: Bringing Lean Back to the U.S.A.
2. Bringing the Toyota Production System to the United States: A Personal Perspective
3. Japanese Education and Its Role in Kaizen
4. Lean Manufacturing Practices at Small and Medium Sized U.S. Parts Suppliers: Does it Work?
5. Transforming a Plant to Lean in a Large, Traditional Company: Delphi Saginaw Steering Systems, GM
6. Making Leather Leaner: The Garden State Tanning Story
7. Learning About Lean Systems at Freundenberg-NOK: Where Continuous Improvement Is a Way of Life
8. The Donnelly Production System: Lean at Grand Haven
9. Implementing Lean Manufacturing at Gelman Sciences
10. Cedar Works: Making the Transition to Lean
11. Operational Excellence: A Manufacturing Metamorphosis at Western Geophysical Exploration Products
12. The Success and Failures of Implementing Continuous Improvement Programs: Cases of Seven Automotive Parts Suppliers
13. Lean Production-The Challenge of Multidimensional Challenge
14. Crossroads: Which Way Will You Turn on the Road to Lean?
15. Conclusion: What We Have Learned About Becoming Lean

Reviews

Review By: John Shook, Director, Japan Technology Management Program, U of Michigan - June 1, 2004
"Becoming Lean implies a journey. We will reach our destination when we apply the philosophies underlying lean to develop our own lean system. There's no reason not to start trying. There are no experts, just people with more experience. The longer we wait, the more experience our competitors will have when we start."

Review By: James Womack, Author of The Machine that Changed the World - June 1, 2004
"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."

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	Becoming Lean: Inside Stories of U.S. Manufacturers Author: Jeffrey Liker Product Code: 1737 ISBN: 978-1-56327-173-1 Pages: 517 Binding: Hard Cover Price: $40.00 Detailed, first-hand accounts of lean production implemented by American firms. The best-seller contains performance records, real numbers to back up the power of going lean, lessons learned in the process of change (both logistics and people issues), and a realistic account of the journey to lean.
	Creating Lean Corporations: Reengineering from the Bottom Up to Eliminate Waste Author: Jeffrey Morgan Product Code: 3241 ISBN: 978-1-56327-324-7 Pages: 272 Binding: Hardcover Price: $40.00 This book is for business process managers (especially lean leaders) who seek to reengineer their business processes using lean principles.
	Creating a Lean Culture: Tools to Sustain Lean Conversions Author: David W. Mann Product Code: 3225 ISBN: 978-1-56327-322-3 Pages: 200 Price: $35.00 2006 SHINGO PRIZE for EXCELLENCE in MANUFACTURING RESEARCH Creating a Lean Culture helps lean leaders succeed in their personal batch-to-lean transformation. It provides a practical guide to implementing the missing links needed to sustain a lean implementation. Mann provides critical guidance on developing and using the key elements of a lean management system, including: leader standard work, visual controls, daily accountability processes, maintaining a process focus, managing key HR issues, and much more.
	Eaton Lean System: An Interactive Introduction to Lean Manufacturing Principles Product Code: Eaton ISBN: 978-1-56327-261-5 Binding: CD-ROM Price: $750.00 Are you looking for a way to introduce fundamental concepts of lean to your workforce? Are you wondering how to do it? Look no further. The Eaton Lean System is the way to deliver fundamentals of lean to your workforce.
	Evolution of Manufacturing Systems at Toyota Author: Takahiro Fujimoto Product Code: 3204 ISBN: 978-0-19-512320-3 Price: $39.95 Through original field studies, historical research, and statistical analyses, this book shows how the Toyota Motor Corporation built - and continues to build - distinctive capabilities in production, product development, and supplier management as part of a total system.
	Fast Track to Waste-Free Manufacturing: Straight Talk from a Plant Manager Author: John W. Davis Product Code: 2121 ISBN: 978-1-56327-212-7 Pages: 277 Binding: Hard Cover Price: $45.00 John W. Davis details a new and proven system called Waste-Free Manufacturing (WFM) that rapidly deploys the lean process.
	Fast Track to Waste-Free Manufacturing on Audio Cassette: Straight Talk from a Plant Manager Author: John W. Davis Product Code: 2784 ISBN: 978-1-56327-278-3 Pages: 296 Binding: Cassette Price: $37.95 In Fast Track to Waste-Free manufacturing: Straight Talk from a Plant Manager, John Davis details a new and proven system called Waste-Free Manufacturing (WFM) that rapidly deploys the lean process. This book, now available on Audio Cassette and CD, will give you step-by-step directions for making rapid, lasting changes.
	Fast Track to Waste-Free Manufacturing on Compact Disc: Straight Talk from a Plant Manager Author: John W. Davis Product Code: 2792 ISBN: 978-1-56327-279-0 Pages: 296 Binding: CD (Audio) Price: $37.95 In Fast Track to Waste-Free Manufacturing: Straight Talk from a Plant Manager, John Davis details a new and proven system called Waste-Free Manufacturing (WFM) that rapidly deploys the lean process. This book, now available on Audio Cassette and CD, will give you step-by-step directions for making rapid, lasting changes.
	The Fundamentals of Lean DVD Author: Productivity Press Development Team Product Code: 339X ISBN: 978-1-56327-339-1 Binding: DVD Price: $495.00 Now In DVD! Familiarize your company with the basic lean concepts.
	Identifying Waste on the Shopfloor Author: Productivity Press Development Team Product Code: 2873 ISBN: 978-1-56327-287-5 Pages: 89 Binding: Paperback Price: $25.00 In Identifying Waste on the Shopfloor, the Productivity Development Team has created an excellent guide to quickly understanding, identifying, and eliminating shop floor waste. From inventory waste to process-related waste, Identifying Waste on the Shopfloor covers every type of waste generating event, policy, and mindset. The book then gives you tools to effectively eliminate them from your manufacturing processes.
	Inside the Mind of Toyota: Management Principles for Enduring Growth Author: Satoshi Hino Translator: Andrew Dillon Product Code: 3004 ISBN: 978-1-56327-300-1 Pages: 352 Binding: Hardcover Price: $50.00 This book clarifies the principles through which any enterprise or organization can learn to attain its own sustained growth. The ultimate goal is not to simply mimic Toyota's formula, but to learn from it and, in doing so, surpass it.
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	Lean Culture: Collected Practices and Cases Author: Productivity Press Development Team Product Code: 3268 ISBN: 978-1-56327-326-1 Pages: 160 Binding: Paperback Price: $15.00 Provides a variety of case studies, all focus on cultural issues, ranging from the role of top management, to training and development of workers and managers, to building buy-in and to sustaining the culture.
	Lean Production Simplified, 2nd Edition: A Plain-Language Guide to the World's Most Powerful Production System Author: Pascal Dennis Product Code: 3568 ISBN: 978-1-56327-356-8 Pages: 208 Binding: Paperback Price: $35.00 2006 SHINGO PRIZE WINNER for EXCELLENCE in MANUFACTURING RESEARCH Lean Production Simplified, 2nd Edition is a plain language guide to the lean production system written for the practitioner by a practitioner. It delivers a comprehensive "insider's" view of lean manufacturing. Updated with expanded information, the author helps the reader to grasp the system as a whole and the factors that animate it by organizing the book around an image of a "house of lean production."
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	LeanSpeak Ebook: The Productivity Business Improvement Dictionary Product Code: 2660 ISBN: 978-1-56327-266-0 Binding: E-Book Price: $9.95 Do you ever wish you had a single resource for looking up lean or business improvement jargon?A reference for correct usage, with links between terms? Most importantly, don't you want to know you're getting your information from experts in the field? To address these needs Productivity Press created LeanSpeak - the original and authoritative compendium of improvement terms.
	Modern Approaches to Manufacturing Improvement: The Shingo System Author: Charles J. Robinson Product Code: 64X ISBN: 978-0-915299-64-5 Pages: 420 Binding: Hard Cover Price: $35.00 Learn about quick changeover, mistake-proofing, non-stock production, and how to apply Dr. Shingo's famous scientific thinking mechanism.
	One-Point Lessons: Rapid Transfer of Best Practices for the Shop Floor Author: Productivity Press Development Team Product Code: 2245 ISBN: 978-1-56327-224-0 Pages: 186 Binding: Learning Package Price: $395.00 A one-point lesson is the primary way of communicating information about processes and equipment in an organization. And the best way to learn the technique of one-point lessons is through active participation with Productivity's newest toolkit.
	The Sayings of Shigeo Shingo: Key Strategies for Plant Improvement Author: Shigeo Shingo Product Code: 151 ISBN: 978-0-915299-15-7 Pages: 207 Binding: Hard Cover Price: $45.00 Using hundreds of real-life examples, Shingo describes simple ways to identify, analyze, and solve problems in the workplace.
	Standard Work for the Shopfloor Author: Productivity Press Development Team Product Code: 2733 ISBN: 978-1-56327-273-8 Pages: 100 Binding: Paperback Price: $25.00 Standard Work for the Shopfloor introduces production teams and managers to basic standard work concepts and applications. Use this book to get everyone on board to maintain quality, efficiency, safety and predictability. This book will enable plant managers to explain and thereby get the support they need from higher management for their performance improvement efforts.
	Study of the Toyota Production System: From an Industrial Engineering Viewpoint Authors: Andrew P. Dillon, Shigeo Shingo Product Code: 178 ISBN: 978-0-915299-17-1 Pages: 291 Binding: Hard Cover Price: $55.00 An industrial engineering rationale for the priority of process-based over operational improvements for manufacturing.
	Toyota Production System: Beyond Large-Scale Production Author: Taiichi Ohno Product Code: 143 ISBN: 978-0-915299-14-0 Pages: 163 Binding: Hard Cover Price: $45.00 With Productivity Press' classic books, you learn from the masters. Taiichi Ohno is considered the inventor of the Toyota Production System and lean manufacturing. And in his book Toyota Production System, the creator of just-in-time production reveals the origins, daring innovations and ceaseless evolution of the Toyota Production System.
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	Toyota Production System on Compact Disc: Beyond Large-Scale Production Author: Taiichi Ohno Product Code: 2679 ISBN: 978-1-56327-267-7 Pages: 180 Binding: CD (Audio) Price: $29.95 Improve your manufacturing operation using proven methods from the "founding father of just-in-time" and leading developer of the Toyota Production System. This classic book, now available on audio tape and CD, contains the first information ever translated into English on the Toyota Production System.
	Training Within Industry: The Foundation of Lean Author: Donald A. Dinero Product Code: 3071 ISBN: 978-1-56327-307-0 Pages: 356 Binding: Hardcover Price: $45.00 2006 Shingo Prize for Excellence in Manufacturing Research Training Within Industry, by Donald Dinero, explores a crucial piece of a Lean initiative that has been overlooked throughout U.S. industry. The Training Within Industry (TWI) program — developed by the United States during World War II — has been used by Toyota for decades! This powerful program standardizes training processes and assists front-line supervisors in teaching new operations to workers quickly and effectively.
	The TWI Workbook: Essential Skills for Supervisors Authors: Patrick Graupp, Robert J. Wrona Product Code: 3152 ISBN: 978-1-56327-315-5 Pages: 224 Binding: Paperback Price: $45.00 Readers of The TWI Workbook will be able to perform detailed step-by-step methods for the three most essential tasks people in management positions must perform: the ability to teach someone to do a job, the ability to improve on those jobs, and the ability to build positive employee relationships with the people they lead.