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LEAN IN ACTION

SHARED EXPERIENCE FROM 140 COMPANIES

selected excerpts EDITOR REVIEWS
LEAN Practices
LEAN IN ACTION
SHARED EXPERIENCE FROM 140 COMPANIES
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SELECTED CHAPTERS

CHAPTER 07
SMED
In short series production the time for readjust or change the equipment may be commensurate and even longer than the time for execution of the series. The short series is a chimera if the readjustment and change of equipment is slow
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CHAPTER 09
ONE-PIECE FLOW
One of the ways to achieve continuous and levelled flow is to abandon the batch model and reorganize the production into a system of related One-Piece Flows – the products to be made one by one and the production processings to be carried out one by one.
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CHAPTER 13
QUEUES
The three ways to reduce the queues in the production are considered: 1) Regulation of the production capacities. 2) Disciplining the queues of customer and production orders. 3) Shortening the times of main and auxiliary operations.
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APPENDIX 2
WORKING WITH SUPPLIERS
Мost of foresighted companies have already realised that they need long-term business with a small number of skilled and loyal suppliers in order to be able to reduce costs and have the certainty that performance would always be stable.
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ABSTRACT

Reduce waste. Speed up production. Increase profits

What makes a business successful? How do you increase revenue and reduce costs?

Above all, how do you identify and eliminate internal losses resulting from resources and activities that are redundant for the client? In most businesses, neither sales prices nor resource prices can be significantly influenced. So what else could be done? No more than what happens between the input and output of the company, i.e. the capacity and efficiency of internal processes. This is where the company creates added value.

For decades, first the automotive industry, and then a number of other industries have been following the path of Lean in search of greater efficiency.

Lean is a philosophy of setting the work free of resources and activities which are redundant for the clients, since they do not create any value for them. Lean is a system of organizational and sociocultural tools, the knowledge of which facilitates and guarantees an effective business. Lean is a model for  manufacturing in short series and broad portfolio, within tight timeframes, at low cost, and with quality in mind. Lean is a recipe for efficiency. Each company has a recipe of its own, but the goal is still the same – a highly efficient business!

The book “Lean in Action" is a guide to introducing the principles and tools of Lean. The book shares the knowledge and experience gathered from observations and analysis of the application of Lean in 140 industrial companies in Bulgaria. They have proven, and continue to prove, that Lean is not only universally applicable, but it also ensures positive results at all times. Acknowledged and comprehended first hand, practical experience is described and rationalized. The success achieved and lessons learned in hard times point out the right way, prevent mistakes, and reduce risks.

The book presents all the practically proven working tools of Lean, starting from searching for Muda and their analysis (losses from surpluses), 5S System in Workplace and Value Stream Mapping, going through Short Series Production, Single-Minute Exchange of Die, Total Productive Maintenance, On-Piece Flow & Continuous Flow & Leveling Flow, ultimately reaching the emanation of Lean – the ingeniously simple and effective system Production & Delivery Just in Time.

They are illustrated with useful examples of the application of the methods of Bottleneck Management, Queues Reduction, and Stocks Control when solving Lean cases.

Daily Management and the work of Kaizen teams are further discussed as means to maintain results achieved by other methods.

The synergy between Lean Production and Total Quality, Industrial Logistics, and Six Sigma is presented.

Working rules are provided for submission and selling ideas, seeking group consensus, preventing and overcoming resistance, and motivating to participate in improvements. Different models for managing Lean Transformation are compared.

The book is a practical guide for anyone interested in Lean Production, planning to carry out Lean Transformation for their business, or already on the way to achieve it.

BRIEF TABLE OF CONTENTS OF THE BOOK "LEAN IN ACTION"

Chapter 01. Key Ideas of Lean
Chapter 02. Description and Measurement of Production
Chapter 03. The Seven Muda
Chapter 04. Value Stream Mapping
Chapter 05. 5S System in Workplace
Chapter 06. Short Series Production
Chapter 07. Single-Minute Exchange of Die (SMED)
Chapter 08. Total Productive Maintenance (ТРМ)
Chapter 09. One-Рiece Flow and Continuous Flow
Chapter 10. Inverse Planning and Pull Flow Chapter 11. Just-in-Time Production and Delivery
Chapter 12. Lean Production and Bottleneck Management
Chapter 13. Lean Production and Queues Management
Chapter 14. Lean Production and Stock Management
Chapter 15. Daily Management
Chapter 16. Overall Participation in Continuous Improvements
Chapter 17. Lean Thinking. Lean and Anti-Lean
Chapter 18. Organization for Lean Transformation
Chapter 19. The Strange Human Aspects of Lean Transformation
Chapter 19.01. Rules for Persuasion and Selling Ideas
Chapter 19.02. Methods of Achieving Group Consensus
Chapter 19.03. Overcoming Resistance to Change
Chapter 19.04. Inclusion and Motivation to Participate in Improvements
Chapter 19.05. Overall Personnel Effectiveness
Chapter 20. Lean Production and Other Approaches to Efficiency
Appendix 1 – Total Quality Principles
Appendix 2 – Rules for Working with Suppliers
Appendix 3 – Practical Tasks With Solutions
Appendix 4 – Abbreviations and Terms in Alphabetical Order
Appendix 5 – Self-Assessment Test
Appendix 6 – Bibliography

READER REVIEWS

ABB ITALY
LUIGI AMORESE, GLOBAL QUALITY
Luigi Amorese, Global Quality Lean in Action is a great read for newcomers as well for experience practitioners, who would like to deep dive into the world of Lean. The concepts are explained in a very detailed and catchy manner, well blended with real life examples. I highly recommend the book to all specialist, managers and entrepreneurs, who will find a powerful toolbox and knowledge source to boost their businesses performance!
VAPTECH SA
ALEXANDROS VOREOPOULOS, CEO
The book has been used by my team and personally by me as the main working manual for management tools implementation. Author’s clear tongue and high value information and guidance as well excellent structure turns this book to the ultimate guidance for processes optimization. By implementing the lean practices as described in this book we have seen through the years improved quality, productivity and on time delivery, improved customer satisfaction, improved employee satisfaction and overall sustainability. Our company VAPTECH facing new competition and changing macroeconomic conditions was in need of help to survive for the long-term and Lean practices, done right, made us more flexible and adaptable to changes. I highly recommend this book to the visioners who want to progress through continuous improvements and innovations.
LUFTHANSA TECHNIK SOFIA
DANIEL HOFFMANN, CEO
At Lufthansa Technik Sofia we are having a strong emphasis on Continuous Improvement. Our dedicated team of Process Specialists is constantly identifying areas for improvement in order to drive production performance in coordination with the operations departments. The book "Lean in Action" is supporting the task effectively by translating the ideas and principles of Lean Management into real value-adding improvements in the company that impact efficiency, thus driving up profitability.
LIEBHERR APPLIANCE
CHRISTINE MOLL, LEAN MANAGER
This book proves to be an outstanding entry point into the fascinating realm of Lean Management. Its strength lies not only in its theoretical excellence but also in its practical applicability. It offers a step-by-step guide on how to effectively implement Lean principles across various areas of a business. From the production line to office work, the author provides valuable insights and clear action recommendations. One of its strengths is its clarity and comprehensibility. The author has managed to distill complex concepts into a digestible form without sacrificing depth and relevance. This makes it an excellent starting point for anyone seeking to introduce Lean Management in their company or improve existing approaches. It is not only informative and well-structured but also highly accessible, appealing to a broad readership and inspiring them to actively apply Lean Management principles.
MELEXIS BULGARIA
SYLVAIN COLLOT, SITE MANAGER
A fine illustration and effective demonstrations of the application of Lean principles and methodology in any industrial environment. It is a practical, useful and essential guide in our pathways towards excellence! A reference work for all!
METAL TECHNOLOGY GROUP SA
KRASIMIR DACHEV, PRESIDENT
The author presents Lean as a philosophy, ideology, and action. All Lean principles and tools are thoroughly examined. The main focus of the book is Lean transformation: how to organize and manage it. The basic methods, terminology and application options are explained in detail. Research and analytics are followed by examples of different business approaches for accelerating and smoothing out processes by minimising and eliminating losses. The author jumps easily from the complicated terminology of Kaizen, Kaikaku, Gemba, Muda, Mura, and Muri to the human aspects of Lean change. The ways of preventing and overcoming the resistance of employees and managers to Lean thinking are presented with short, captivating and at the same time funny examples from Bulgarian practice and national psychology. The essence of the processes is captured, the steps for realization and the possible risks for implementation are described. The book "Lean in Action" is valuable for the expert help and solutions that it provides to all professionals in the industry and business. The author has transformed the book into not just a voluminous handbook of information but a shared space for all those tempted by Lean ideology. He integrates science, world industry practice and countless examples from multiple Bulgarian companies in only 800 pages. What could possibly prove better the opportunities and benefits that Lean can offer?and smoothing out processes by minimising and eliminating losses. The author jumps easily from the complicated terminology of Kaizen, Kaikaku, Gemba, Muda, Mura, and Muri to the human aspects of Lean change. The ways to prevent and overcome the resistance of employees and managers to Lean thinking are presented with short, captivating, and at the same time funny examples from the Bulgarian practice and national psychology. The essence of the processes is captured; the steps for introduction and the possible risks for implementation are described. Lean Practices is valuable for the expert help and solutions that it provides to all professionals in the industry and business. The author has transformed the book into not just a voluminous handbook of information but a shared space for all those tempted by Lean ideology. He integrates science, world industry practice, and countless examples from multiple Bulgarian companies in only 700 pages. What could possibly prove better the opportunities and benefits that Lean can offer?
IDEAL STANDARD – VIDIMA SA
VALENTIN GANEV, CEO
Authentic. Practical. Influential. This book is as fascinating as its author himself who takes us back to the spirit of best Bulgarian manufacturing practices without the Lean label and today’s generation of modern technology to which Lean action has become a standard.
OPTIX SA
IVAN CHOLAKOV, CEO
What is most precious in this book is the comprehensive overview of the Lean matter and the easily comprehensible author’s summaries based on an analysis of real-world experience, outlined with an impressive number of examples collected from Bulgarian companies.
LUFTHANSA TECHNIK SOFIA SA
STEFAN MARKOV, IMPROVEMENT DIREKTOR
Finally, we have a complete narrative about Lean and its applications in comprehensible Bulgarian, without foreign language and ambiguities. I recommend this book to all those who wish to discover and understand the possibilities for improvement and optimization of their business processes. Lean ideology provides such possibilities, and Prof. Kehayov’s book explains how to do it in practice. It shows how to adapt theory to your activities and also allows you to learn from the experience of a number of companies in Bulgaria. This book succeeds in being a helpful guide for more successful development, throwing light on different paths, many of which we have built together in Bulgaria. Come and join this journey.
FESTO PRODUCTION SA
GEORGI ATANASOV, CEO
To know and apply Lean means to change your mindset and behaviour generally. Not only in the business environment but also in your day-to-day life. This book will help you get to know Lean methods and tools and get down the road to your Lean transformation.
SIEMENS ENERGY BULGARIA SА
TODIN PANAYOTOV, CEO
Be successful, be Lean! Read and learn how! The book is based on the rich theoretical and practical experience of the author and his team. Read it and enhance your knowledge.
ABB BULGARIA – RAKOVSKI SA
STOYAN IVANOV, LEAN MANAGER
This is a book written with great desire and hard work, suitable for both beginners and established professionals. It is full of examples: from theory to real-world practice. It provides proper guidance on how to approach different situations, what to choose and keep track of, in order to solve problems or implement new ideas. The wording is accurate, leading to a correct interpretation of the methods and methodology. In practical terms, the book will be relevant for many years to come and could become exemplary. Many thanks to the author for giving me the chance to read this book.
UNIVERSITY OF MINING AND GEOLOGY
PROF. ELKA SHALAMANOVA
A timely arrival. The book is a guide on best manufacturing practices with many examples from our own companies that apply Lean tools. It will be of benefit to undergraduates, graduates and Ph.D. students in higher engineering and business schools. The leaders who wish to optimise their business processes, will find a number of useful tools in the book. Teachers will benefit from the multiple knowledge tests applied in the book. The author is a captivating narrator and his language is simple and understandable.
SI COMMERCIAL SA
SOTIR NEMOV, PRESIDENT
It’s a pleasure to read and think about all that is written in this book. My colleagues and I have discussed it in depth, chapter by chapter, and asked ourselves what do we need to do to make our company a real Lean company.
ZOBELE BULGARIA SA
YORDAN LAMBREV, CEO
Leading manufacturing practices are presented in a simple and pleasant-to-read language, supported by examples from Bulgarian industry. The handbook is an extremely helpful read for both beginners in Lean methods and those who are experienced but need a new source of inspiration and access to analyses, as well as tested and working ideas.
UNIVERSITY OF ARCHITECTURE, CIVIL ENGINEERING AND GEODESY
PROF. JULIETA MANCHEVA
Admiration for the author of “Lean in Action” for creating a meaningful, interesting, accessible and helpful work. Prof. Anastas Kehayov’s book is intended for people with a practical mindset, an affinity for optimization and innovative thinking. I have no doubt the book will have great success!
SENSATA TECHNOLOGIES SA, LEAN MANAGER
IVANKA TYANKOVA
I have one word only to describe the book: captivating. It takes the reader down to the Lean adventure and opens the mind to the fact that every day, we all live Lean without even realising it.
UNIVERSITY OF CHEMICAL TECHNOLOGY AND METALLURGY
PROF. DIMITAR TENCHEV
The book LEAN IN ACTION, authored by Prof. Anastas Kehayov, is based on the practical experience of 140 Bulgarian and foreign companies from almost all sectors of industry and services. LEAN IN ACTION is a successful combination of a textbook, a reference book and a manual for the practical implementation of Lean principles and tools. LEAN IN ACTION demonstrates the relationship and dialectic of Kaizen and Kaikaku as two complementary approaches in the processes of continuous improvement. The principles of Lean Production are presented and explained as the implications and practical applications of some of the principles of the Total Quality Management. The fabric of Lean & Six Sigma is explained against the backdrop of the evolution of Statistical Process Control and as part of the quality assurances set out in the automotive specification IATF 16949. LEAN IN ACTION captivates the reader both with its fascinating style and with convincing examples from various spheres of human activity. The examples are not only from industry, but also from most various other branches of the real sector and services, as well as from our everyday life. A valuable feature of LEAN IN ACTION is the strong emphasis on the organisational and social aspects of the work on the implementation of Lean tools in practice. LEAN IN ACTION is a useful advisor and assistant for lecturers, graduate students and students, working in the field of modern management.
INTERNATIONAL HIGHER BUSINESS SCHOOL
PROF. NEDKA GATEVA
The book “Lean in Action” presents modern management approaches and manufacturing practices, the effectiveness of which has been proven in the experience of thousands of successful companies worldwide. This is a textbook, a practical guide, and an interesting, even amusing read. Using unconventional, concise, and vivid language, inspired illustrations, and eloquent examples from 140 companies in Bulgaria, the book conveys messages and lessons which evoke reflection in a wide range of managers and professionals from all industries, and provokes them with questions. The merits of the book are attributable to the talent of its author, with a brilliant erudition, serious acedmic education, and rich consultancy experience. This is all the knowledge that he is called upon to share, and does so in a convincing way. This book also enthralls with its suggestions on the life philosophy of each one of us
ANASTAS KEAHYOV
ABOUT THE AUTHOR OF LEAN PRACTICES
Professor Anastas Kehayov has over 50 years of experience in teaching and coaching top management executives of more than 800 Bulgarian and international companies. His students are over 18,000 senior- and middle managers of industries and the real sector.

He graduated in engineering, specialising in Automation and Telemechanics from the Technical University of Sofia in 1970. He has long-term specialisations and internships in Macro Forecasting and Planning Programming Budget System at the Institut international d'administration publique de Paris (1973) and in Informatisation des systèmes administratives at the Centre d'etudes practiques en informatisation et automatisation de Rocquencourt (1979).

He has a Ph.D. in Theory of Stocks (1976) and an academic rank in Strategic Planning (1984).

He spent two years as a scientific secretary at the Department of Mathematical Modeling (1983-1984) and eight years as a head of the Department of Strategic Planning (1984-1992) at the Institute of Public and Economic Management in Sofia.

He is the founder of one of the most successful teaching and coaching businesses in Bulgaria, Alpha Quality, and has been managing it from 1988 to date.

In Bulgaria, Professor Anastas Kehayov is recognised as a doyen in the field of Total Quality Management and one of the pioneers in the field of Innovations Marketing, Strategic Planning, Human Capital Development, Industrial Logistics, and Organisational Design of company management systems.

He is the author of five books on modern methods and systems for effective company management.

He has a number of awards for teaching and research, such as the Order of Saint Cyril and Methodius for merits in the field of education and science

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