Chapter 1

Principles of Lean Management

Origins of Lean (Toyota Production System - TPS)

medium • 1 min read

The five lean principles (Value, Value Stream, Flow, Pull, Perfection)

medium • 2 min read

Identify and eliminate the 7 wastes (Muda, Mura, Muri)

medium • 3 min read

Lean culture and respect for people

medium • 4 min read

Differences between Lean, Six Sigma, and traditional mass production

medium • 5 min read

Chapter 2

Value Stream Mapping (VSM)

Purpose and components of VSM

medium • 1 min read

Current state mapping and identifying bottlenecks

medium • 2 min read

Future state mapping and ideal state

medium • 3 min read

Cycle time, lead time, and TAKT time calculation

medium • 4 min read

Implementing VSM improvements

medium • 5 min read

Chapter 3

Just-In-Time (JIT) and Flow Concept

JIT concepts and prerequisites

medium • 1 min read

Pull systems vs Push systems

medium • 2 min read

Kanban system design and card calculation

medium • 3 min read

Continuous flow manufacturing and cellular layouts

medium • 4 min read

Heijunka (Production leveling and smoothing)

medium • 5 min read

Chapter 4

Standardization and visual Controls

Standardized work and standard operating procedures (SOPs)

medium • 1 min read

5S methodology (Sort, Set in order, Shine, Standardize, Sustain)

medium • 2 min read

Visual management and Andon systems

medium • 3 min read

Jidoka (Autonomation and built-in quality)

medium • 4 min read

Total Productive Maintenance (TPM) and OEE

medium • 5 min read

Chapter 5

Continuous Improvement and Setup Reduction

Kaizen events and rapid improvement blitzes

medium • 1 min read

Single Minute Exchange of Die (SMED) methodology

medium • 2 min read

Internal vs External setup time conversion

medium • 3 min read

Lean in services and administration (Lean Office)

medium • 4 min read

Hoshin Kanri (Policy Deployment)

medium • 5 min read