Mistake Proofing and Value Stream Management Books and Videos

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Mistake Proofing and Value Stream Management

40 Top Tools for Manufacturers: A Guide for Implementing Powerful Improvement Activities		We know how important it is for you to have the right tool when you need it. If you're a team leader or facilitator in a manufacturing environment, you've probably been searching a long time for a collection of implementation tools tailored specifically to your needs. Well, look no further.

5S for Operators: 5 Pillars of the Visual Workplace		The five pillars of the visual workplace: sort, set in order, shine, standardize and sustain are the most fundamental and often overlooked aspects in continuous improvement initiatives. Together, these concepts form the framework of the 5S System, a set of principles whose simplicity often betrays its powerful impact on the workplace.

5S for the Office: Organizing the Workplace to Eliminate Waste		Although office and administrative activities are usually 60% of the production costs in most manufacturing organizations, these areas often get excluded during Lean initiatives. To achieve Lean, office activities must fully support shop floor manufacturing operations to eliminate waste. The adoption of 5S throughout all office and administrative functions is the first step to increase efficiency.

A Lean Supply Chain at John Deere DVD		This video DVD is about the successful partnership between John Deere in Horicon, Wisconsin and one of its suppliers - the R&B Machining and Grinding Company located in Racine, Wisconsin. It provides an opportunity to take a look inside John Deere's supply chain - find out what changes were required to "learn their supply chain."

A Revolution in Manufacturing: The SMED System		Written by the industrial engineer who developed SMED for Toyota, this book contains hundreds of illustrations and photographs, as well as twelve chapter-length case studies. Here are the most complete and detailed instructions available anywhere for transforming a manufacturing environment to speed up production and make small lot inventories feasible.

Accelerated Product Development: Combining Lean and Six Sigma for Peak Performance		In Accelerated Product Development: Combining Lean and Six Sigma for Peak Performance, Clifford Fiore provides the blueprint for implementing the key elements for improving the product development process. His innovative and powerful work represents the first book to couple the proven concepts of Lean and Six Sigma with the engineering processes of product development.

Advanced Quality Planning: A Commonsense Guide to AQP and APQP		Advanced Quality Planning: A Commonsense Guide to AQP and APQP is the first book dedicated to explaining with clarity and detail the total advanced quality planning (AQP) process and how to set quality planning in the framework of a business strategy. The book provides a close look at the basic and advanced concepts of AQP so that both the novice and experienced user will be able to apply AQP appropriately and effectively.

Autonomous Maintenance DVD: Shopfloor TPM Implementation		With Productivity's Autonomous Maintenance video training series, you'll learn how to unleash the hidden potential on your shopfloor and dramatically lower your production costs.

Autonomous Maintenance for Operators		TPM leads to soaring productivity when your operators are positively and energetically involved in the maintenance of their own equipment. Autonomous Maintenance for Operators teaches specific autonomous maintenance activities.

Autonomous Maintenance in Seven Steps: Implementing TPM on the Shop Floor		Autonomous maintenance is an especially important pillar of Total Productive Maintenance (TPM) because it enlists the intelligence and skills of the people who are most familiar with factory machines-- equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program.

Becoming Lean: Inside Stories of U.S. Manufacturers		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.

CEDAC: A Tool for Continuous Systematic Improvement		When you're trying to improve quality and productivity, it's essential to target the right problems, get the right people involved in solving them, and make sure the solutions work. CEDAC will help you do all three. CEDAC, or Cause-and-Effect Diagram with the Addition of Cards, is a modification of the "fishbone diagram," a standard QC tool. One of the most powerful, yet simple problem solving methods to come out of Japan (Fukuda won a Deming Prize for developing it), CEDAC actually encompasses a whole cluster of tools for continuous systematic improvement.

Concurrent Engineering: Shortening Lead Times, Raising Quality, and Lowering Costs		By simultaneously examining the concerns of design, production, purchasing, finance, and marketing from the very first stages of product planning, concurrent engineering makes doing it right the first time the rule instead of the exception. This should be the first book managers read when they are ready to eliminate waste in the product development process.

Creating Continuous Flow: An Action Guide for Managers, Engineers & Production Associates		Creating Continuous Flow narrows the focus of Learning to See from the door-to-door value stream perspective to achieving true continuous flow at your critical pacemaker processes.

Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand		Creating Mixed Model Value Streams is the new textbook for implementing lean in complex environments. When faced with complex or unique situations companies often disregard lean principles and fall back on previous practices. In this book, Kevin Duggan describes the lean techniques that can be used when faced with difficult situations such as high product mix, scheduling problems, shared resources, and unstable customer demand.

Creating Your Lean Future State: How to Move from Seeing to Doing		In Creating Your Lean Future State: How to Move from Seeing to Doing, Tom Luyster and Don Tapping detail the implementation of lean after the creation of current and future state maps. Follow the case study of a manufacturing company that has already created a Future State Map, as the authors show step-by-step how to focus on key information, visually manage product flow, and level production.

Custom Kanban: Designing the System to Meet the Needs of Your Environment		In Custom Kanban: Designing the System to Meet the Needs of Your Environment, Raymond Louis helps you to develop and implement a correct and successful kanban system by selecting appropriate kanban techniques based on the specific environmental factors and needs of your company.

Developing a Lean Workforce		Changing an organization from a mass manufacturing environment to a lean environment is significant and affects all levels of the company if the implementation is done correctly. Many times, however, lean implementers become so involved with the nuts and bolts of lean implementation that the "people" side of the business is neglected.

DOE Simplified: Practical Tools for Effective Experimentation		In DOE Simplified - a comprehensive new introductory text geared towards readers with minimal statistical background - the authors take a fresh and lively approach to learning the fundamentals.

Easier, Simpler, Faster: Systems Strategy for Lean IT		To enhance and sustain its lean journey, a company must implement information systems that fully support and enhance the lean initiative. In Easier, Simpler, Faster: Systems Strategy for Lean IT, Jean Cunningham and Duane Jones introduce a case study of an actual lean implementation involving an IT system of a mid-size manufacturer, highlighting the IT issues that they faced during their lean transformation.

Eliminating Minor Stoppages on Automated Lines		Stoppages of automated equipment lines adversely affect productivity, cost, and lead time. Such losses make decreasing the number of stoppages a crucial element of TPM. Kikuo Suehiro has helped companies such as Hitachi achieve unprecedented reduction in the number of minor stoppages. In this explicitly detailed book, he presents a scientific approach to determining the causes of stoppages and the actions that can be taken to diminish their occurrence.

Focused Equipment Improvement for TPM Teams		As distinguished from autonomous maintenance, where the main goal is to restore basic conditions of cleanliness, lubrication, and proper fastening to prevent accelerated deterioration, FEI looks at specific losses or design weaknesses that everyone previously thought they just had to live with.

Implementing TPM: The North American Experience		Total Productive Maintenance (TPM) is an extremely effective strategy for increasing industrial competitiveness in today's worldwide economy. Enlightened company leaders are recognizing that TPM is a "best of class" manufacturing improvement process. Yet some U.S. firms have been only partially successful in implementing a TPM program.

Introduction to Quality Control		Introduction to Quality Control is highly recommended reading for people of all levels already working in quality control as well as those about to enter the field. It may be the best introduction to this vitally important topic you will ever find.

Kaizen for Quick Changeover: Going Beyond SMED		Changeovers in 3 minutes or less! That is the result of the process described in this book. Picking up where Dr. Shingo's Single Minute Exchange of Die left off, it streamlines the process even further to reduce changeover time and cut staffing requirements in half simultaneously!

Kaizen for the Shopfloor		The philosophy of kaizen, which simply means continuous improvement, is the starting place for all lean production improvements. Kaizen events are opportunities to make focused changes in the workplace. Kaizen for the Shopfloor takes you through the critical steps in conducting a very effective kaizen event - one that is well planned, well implemented, and well documented.

Kanban for the Shopfloor		Kanban is the name given to the inventory control card used in a pull system. The primary benefit of kanban is to reduce overproduction -- the most critical of the seven deadly wastes. A kanban system produces exactly what is ordered, when it is ordered, and in the quantities ordered.

Kanban for the Shopfloor Learning Package		Topics include: The difference between kanban and conventional ordering systems. Types of kanbans. Six rules for optimizing a kanban system. How to use line balancing and load leveling in regards to takt time and kanban. When and how to circulate kanban cards. How to reduce the number of kanbans. Using kanban as a visual system.

Kanban Systems DVD		This video DVD will introduce you to the basics concepts of kanban, demonstrate what kanban systems are available, how they work, and where they will be successful. Kanban Systems shows you how lean technique controls inventory to better respond to customer demands.

Kanban y JIT en Toyota		Este libro ofrece una introducci?n clara y completa al "Just-in-Time" y sigue siendo uno de nuestros ?xitos de mayor venta. El texto esta basado en seminarios dictados por Taichi Ohno, creador del Just-in-Time para entrenar a los suplidores de Toyota.

Lean Assembly: The Nuts and Bolts of Making Assembly Operations Flow		With examples drawn from aerospace, electronics, household appliance, personal products, and automotive industries, Lean Assembly covers the engineering of assembly operations through.

Lean Logistics: The Nuts and Bolts of Delivering Materials and Goods		Are your warehouses full while production is stopped by shortages? Do you know what you have, and when the next replenishments will come? Do your customers complain that your lead times are too long and that your deliveries are late? Does the volume of your logistics activity vary erratically?

Lean Software Strategies: Proven Techniques for Managers and Developers		Lean production, which has radically benefited traditional manufacturing, can greatly improve the software industry with similar methods and results. This transformation is possible because the same overarching principles that apply in other industries work equally well in software development.

Lean Thinking, Second Edition: Banish Waste and Create Wealth in Your Corporation		The authors begin by summarizing the five inherent principles in any lean system: Correctly specify value so you are providing what the customer actually wants Identify the value stream for each product family and remove the wasted steps that don't create value but do create muda (waste) Make the remaining value-creating steps flow continuously to drastically shorten throughput times

Learning to See: Value Stream Mapping to Add Value and Eliminate Muda		Much more important, these simple maps - often drawn on scrap paper - showed where steps could be eliminated, flows smoothed, and pull systems introduced in order to create a truly lean value stream for each product family.

Make No Mistake!: An Outcome-Based Approach to Mistake Proofing		With C. Martin Hinckley's new book Make No Mistake! An Outcome Based Approach to Mistake-Proofing, that vision can become a reality. If you work for a company that emphasizes traditional quality control methods, it's unlikely that you've seen defects eliminated despite your substantial efforts.

Mistake-Proofing for Operators Learning Package		The Zero Quality control system (ZQC) is a mistake-proofing approach that prevents defects by monitoring process conditions at the source and correcting errors that would cause defects. In this breakthrough approach, mistake-proofing devices called poka-yoke are used to check and give feedback about each product or operation in the process, not just a sample.

Mistake-Proofing for Operators: The ZQC System		The Zero Quality Control System (ZQC) is a mistake-proofing approach that prevents defects by monitoring processing conditions at the source and correcting errors that cause defects. Since it is human nature to make mistakes, ZQC does not blame people for errors, but instead finds ways to keep errors from becoming defects.

OEE for Operators: Overall Equipment Effectiveness		Overall Equipment Effectiveness (OEE) is a crucial measure in TPM that tells you how well your equipment is running. It links three elements in one percentage: the time the machine is actually running, the quantity of products the machine is turning out, and the quantity of good output.

P-M Analysis: An Advanced Step in TPM Implementation		In this large-format implementation manual, TPM experts explain P-M Analysis. (A methodology that makes zero losses a reality in your TPM program.) P-M Analysis is designed to help your TPM teams analyze and eliminate chronic problems that have been neglected or unresolved in the past.

Poka-Yoke: Improving Product Quality by Preventing Defects		If your goal is 100% zero defects, here is the book for you � a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists.

Practical TPM: Successful Equipment Management at Agilent Technologies		Agilent Technologies, formerly Hewlett-Packard's Test and Measurement Division, operates an integrated circuit fabrication plant in Fort Collins, Colorado. Guided by Masaji Taijiri, the author of 7 Steps to Autonomous Maintenance (see page 34), author Jim Leflar and his team at Agilent developed a complete TPM program for the complex equipment on their shop floor.

Proactive Risk Management: Controlling Uncertainty in Product Development		Proactive Risk Management's unique approach provides: A model of risk that is scalable to any size project or program and easily deployable as the risk management approach built into any product development or project management life cycle.

Process Mastering: How to Establish and Document the Best Known Way to Do a Job		The benefits include: cost reduction; increased productivity; improved safety; higher morale; and the ability to meet the changing expectations of your customers.

Process Problem Solving: A Guide for Maintenance and Operations Teams		To be a successful manufacturing operation, employees must eliminate equipment and production related losses. However, most shopfloor workers don't have the necessary skills to perform the problem-solving tasks that accomplish this goal. They must be trained in the proper methods for logically and systematically discovering the root causes of a situation.

Product Design Review: A Methodology for Error-Free Product Development		The goal of the world class company is to produce a product or service that offers customers the highest quality at the lowest cost and in the shortest time possible. Product Design Review describes a highly effective method for quality control in product design, as well as its applications in a wide variety of business settings.

Pull Production for the Shopfloor		In a "pull" production system, the final process pulls needed parts from the previous process, which pulls from the process before it, and so on, as determined by customer demand. This allows you to operate without preset schedules and avoid unnecessary costs, wastes, and delays on the manufacturing floor.

Quality Function Deployment: Integrating Customer Requirements into Product Design		Quality Function Deployment (QFD) is a method for satisfying customers by translating their demands into design targets and quality assurance points.

Quick Changeover for Lean Manufacturing DVD		This video DVD explores examples of quick changeover in the plastic injection molding, metal stamping and metal cutting industries. Through case studies at four leading companies you will learn how each reduced changeover times to be more responsive to customer needs.

Quick Changeover for Operators Learning Package		Each Quick Changeover for Operators Learning Package includes the following components:

Quick Changeover for Operators: The SMED System		The powerful knowledge contained in this book can make your workplace more productive, your job simpler, and everything more satisfying. It's about how to do equipment or product changeovers in record time--often in less than 10 minutes.

Quick Changeover Simplified: The Manager's Guide to Improving Profits with SMED		Quick Changeover Simplified: The Manager's Guide to Improving Profits with SMED, by Fletcher Birmingham and Jim Jelinek, is for companies that must implement a quick setup and changeover program, but aren't sure how to start.

RSM Simplified: Optimizing Processes Using Response Surface Methods for Design of Experiments		RSM Simplified keeps formulas to a minimum and makes liberal use of figures, charts, graphs and checklists. It offers many relevant examples, with amusing sidebars and do-it-yourself exercises that will lead readers to the peak potential for their product quality and process efficiency.

Seeing the Whole: Mapping the Extended Value Stream		By identifying all the steps and time required to move a typical product from raw materials to finished goods, the authors show that nearly 90 percent of the actions and 99.99 percent of the time required for the value chain's Current State create no value. In addition, the mapping method clearly shows demand amplification of orders as they travel up the value stream, steadily growing quality problems, and steadily deteriorating shipping performance at every point up stream from the customer.

Six Sigma Fundamentals: A Complete Introduction to the System, Methods, and Tools		With a focus on both manufacturing as well as non-manufacturing organizations, Six Sigma Fundamentals demystifies the Six Sigma methodology and provides the reader with a solid understanding of what defines a Six Sigma initiative. Each chapter fully addresses the concepts of the Six Sigma philosophy and explains the methodologies for real-world applications.

Six Sigma Tool Navigator: The Master Guide for Teams		Six Sigma Tool Navigator is the only lean resource that provides a complete compendium of tools for teams engaged in Six Sigma improvement activities. In addition, it offers actual tools, definitions and techniques you need to move your organization closer to producing minimal defects.

SPC Simplified: Practical Steps to Quality		It's still a hands-on manual with practice problems in each module. Written in clear language, it simplifies the essentials for monitoring, analyzing, and improving quality. No mathematical background needed.

Standard Work for the Shopfloor		Standard work is an agreed upon set of work procedures that effectively combines people, materials, and machines to maintain quality, efficiency, safety, and predictability. Work is described precisely in terms of cycle time, work in process, sequence, takt time, layout, and the inventory needed to conduct the activity. Standard work begins as an improvement baseline and evolves into a reliable method. It establishes the best activities and sequence steps to maximize performance and minimize waste.

Statistical Methods for Quality Improvement		The Book: Covers the basic statistical quality tools, including data collection, Pareto analysis, cause-and-effect analysis, histograms, scatter diagrams, control charts, and variance. Provides an introduction to statistical inference. Presents the seven-step problem-solving method known as the "QC Story."

Strategic MRO: A Roadmap for Transforming Assets into Competitive Advantage		Strategic MRO: A Roadmap for Transforming Assets into Competitive Advantage combines the concepts of enterprise asset management and the associated maintenance, repair, and operating/overhaul (MRO) materials supply chain. It introduces the breakthrough Demand Supply Compression (DSC) methodology, which guides an organization's thinking and doing as it seeks performance improvement. Like Lean, DSC provides a practical path forward by changing a mind frame and the way in which work is performed.

Tel-A-Train's 4 Video TPM Series		The video set includes: 4 videos on TPM: Run Time: 74 Min A Participant's Guide Facilitator's Guide TPM pilot flow chart Overhead Transparencies

The Basics of FMEA		Based on requirements established by the big-three automakers, The Basics of FMEA introduces work teams to this valuable tool. Failure Mode and Effect Analysis (FMEA) helps prevent failures, defects, and errors, because the tool identifies special causes of variation before they occur. This is valuable in any quality control or continuous improvement program and the reason that the automotive industry's QS-9000 standard requires their use.

The Basics of Process Mapping		This book contains a case study of both levels of process mapping and guidelines for when to use each type. It also explains the relationship of process mapping to flowcharting. Use it as a wonderful hands-on team resource, a training supplement, and a reference.

The Basics of Quality Auditing		As the latest addition to "The Basics" Series, The Basics of Quality Auditing provides an inexpensive and easy-to-follow WHO, WHAT, WHERE, WHEN, WHY and HOW format that is perfect for training. It discusses the four main questions all audits should answer: Is there a procedure? Is the procedure being followed? Does the procedure meet the needs of the system? and What must be changed or improved to increase the output quality?

The Basics of Reliability		The Basics of Reliability is a handy source for comprehending reliability concepts, interpreting reliability requirements, and understanding reliability reports.

The Complete Lean Enterprise: Value Stream Mapping for Administrative and Office Processes		Most lean initiatives conducted by manufacturers are focused mostly on shop-floor activities � mapping the value stream of raw material to the shop-floor customer. Much of the untapped potential for productivity improvements lies, however, in non-production areas � where the value stream is administrative (i.e., "order to cash"). These "office" value streams directly support the daily production needs of an enterprise.

The Lean Office: Collected Practices and Cases		The Lean Office: Collected Practices and Cases is a compilation of articles previously published in our monthly newsletter, Lean Manufacturing Advisor. These articles discuss lean implementations in non-manufacturing operations, from design to processing invoices to customer service. Most articles are written in the form of case studies.

The Root Cause Analysis Handbook: A Simplified Approach to Identifying, Correcting, and Reporting Workplace Errors		The answer is root cause analysis, a process that allows you to find the cause of single events/problems in the workplace. The Root Cause Analysis Handbook presents a walkthrough example that illustrates the method and shows how to implement it.

The Toyota Product Development System: Integrating People, Process, and Technology		The ability to bring new and innovative products to market rapidly is the prime critical competence for any successful consumer-driven company. All industries, especially automotive, are slashing product development lead times in the current hyper-competitive marketplace. This book is the first to thoroughly examine and analyze the truly effective product development methodology that has made Toyota the most forward-thinking company in the automotive industry.

The Winner's Circle		Featuring Indianapolis 500 winners Danny Sullivan and Rick Mears, this highly motivational video introduces the quick changeover technique invented in Japan. The video compares the way a racing pit crew functions to a die changeover team in a manufacturing environment. It shows how both must function as a cohesive unit to succeed.

TPM for Every Operator		This package covers the main aspects of TPM and begins the education process that will introduce frontline workers to this important manufacturing strategy. The enhanced Leader's Guide includes full discussion guide notes as well as tips for addressing the issues which TPM often raises for operators. An excellent tool for supporting your TPM training initiatives.

TPM for Every Operator Learning Package		This package covers the main aspects of TPM and begins the education process that will introduce frontline workers to this important manufacturing strategy. The enhanced Leader's Guide includes full discussion guide notes as well as tips for addressing the issues which TPM often raises for operators. An excellent tool for supporting your TPM training initiatives.

TPM for Supervisors		The benefits of advanced manufacturing methods can't be realized until they're practiced consistently and proficiently by your entire workforce. Here's a simple, low-cost way to get everyone on board quickly. This small book presents the basic methodology of TPM and focuses on hands-on activities for shopfloor teams to maximize equipment effectiveness.

TPM for the Lean Factory: Innovative Methods and Worksheets for Equipment Management		Lean manufacturing cannot happen in a factory that lacks dependable, effective equipment. Breakdowns and processing defects translate into excess work-in-process and finished inventory, kept on hand "just in case." Recurring minor stoppages force employees to watch automated equipment that should run by itself. TPM gives a framework for addressing such problems, but many companies implement TPM at a superficial level, and the resulting productivity gains fall short of their potential.

TPM for the Lean Factory: Innovative Methods and Worksheets for Equipment Management		Workshop leaders play a central role in your company's efforts to implement TPM. Once your workers have been divided into small groups to learn the fundamentals of TPM, it is the group leader who spearheads ongoing training and implementation activities. With quick-reading, people-oriented practicality, this new book addresses the role of the workshop leader in maximizing the benefits of TPM.

TPM in Process Industries		Process industries have a particularly urgent need for collaborative equipment management systems like TPM that can absolutely guarantee safe, stable operation. Process industry plants must operate continuously for long periods to be cost-effective. Accidents and breakdowns involving even one piece of equipment can shut down an entire plant and endanger life and the environment.

TPM Team Guide		TPM involves employees companywide in preventing equipment abnormalities and breakdowns. The first line of defense: equipment operators-the people most familiar with daily operating conditions. In addition to regular cleaning and inspection, team-based improvement activities make effective use of operators' hands-on knowledge.

Uptime, 2nd Edition: Strategies for Excellence in Maintenance		In today's competitive marketplace, the flow of goods and services to customers must not be hindered by obstacles such as maintenance downtime. To stay on top, managers must implement strategies that keep operations performing at high levels.

Using Lean for Faster Six Sigma Results: A Synchronized Approach		Lean? Six Sigma? or Lean Six Sigma? Which is the right approach for effective continuous improvement? While much has been written on merging Lean and Six Sigma initiatives, this is the first book to detail a logical alternative - a no-nonsense strategy for maintaining the best of both initiatives without diluting either.

Value Stream Management: Eight Steps to Planning, Mapping, and Sustaining Lean Improvements		The Value Stream Management System simplifies the planning process for lean implementation, ensuring quick deployment and greater success. It links the metrics and reporting required by management with the lean tools needed on the manufacturing floor. The central feature of this illustrative and engaging book is the value stream management storyboard, a tool representing an eight-step process for lean implementation.

Value Stream Management for the Lean Office: 8 Steps to Planning, Mapping, & Sustaining Lean Impvmts in Admin. Areas		Bring Lean Improvements to the Administrative Areas of Your Organization! Tapping and Shuker take their Value Stream Management Storyboard and apply its eight-step process in the context of a customer service case study based on an actual implementation. Value Stream Management for the Lean Office will provide you with a complete system for lean implementation in the office.

Value Stream Management Video Set: Eight Steps to Planning, Mapping and Sustaining Lean Improvements		A successful, sustainable lean initiative requires more than just mapping your value stream and making a few improvements. It requires a process to manage the entire lean transformation. This new video series will teach you an exciting eight-step method for creating and applying a systematic process for the implementation of lean manufacturing. You will actually be able to train lean teams in the process and begin using it immediately. Plus, you will see how leading American manufacturing facilities have accomplished their lean transformation.

Zero Quality Control: Source Inspection and the Poka-Yoke System		Shigeo Shingo shows you how this proven system for reducing errors to zero, turns out the highest quality products in the shortest period of time. Provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement.