SELECTED CHAPTERS
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
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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