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Thursday, May 15, 2008

"Reflections On Lean" Book -- With Video!

RichCatalog - Free online book

I'm sure many of you got the email blast from the Lean Enterprise Institute, but this is really cool. It's a free online version of the book "Reflections on Lean." They've improved upon the printed version by incorporating video segments of the people who reflected on Lean.

I'm looking forward to watching more of these videos later. Which is your favorite?

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Saturday, May 10, 2008

"Real Lean," Volumes 1 and 2

I've had the opportunity to read Bob Emiliani's two collections of essays on "Real Lean" and I'm long overdue on posting about them. I'm especially late considering since Volume Three is coming out in June. These books are particularly recommended for those who already have a basic Lean education and some experience (or struggles) with implementing Lean.

Real Lean: Understanding the Lean Management System (Volume One)


In this book, Emiliani introduces the "Real Lean" concept, by which he means the real approach that focuses on both pillars of the Toyota Way:
  1. Continuous Improvement
  2. Respect for People
As Emiliani points out, far too many only focus on the first part -- the tools, improvement, and methods, without focusing on people. When people are implementing Lean with just a short-term focus -- focusing only on numbers or (even worse) slashing headcount, he calls this "Fake Lean." It's pretty similar to my "Lean vs LAME" construct.

Here is Bob's page about the book, with the list of essays and reader reviews.

Real Lean: Critical Issues and Opportunities in Lean Management (Volume Two)

This second volume covers more issues for those who are deep into their Lean journey. For example, chapter 6 is called "We're Beyond That." This is pretty common when a company is a few years into their Lean journey. A company has had success or maybe the executives are bored (or have moved on) and it's time to move "beyond Lean" (if I only had a dollar for each article or webinar that promised what's next "beyond Lean."). Bob emphasizes that Real Lean is a constant mindset and a constant way of managing a business.

Here's Bob's page on Volume Two.

Check out the "Emiliani" link below for discussion about his earlier books and his podcast episodes that we did together.

I'm going to spend some time re-reading some of these essays over the weekend and I might comment more on the ones that were most useful to me in my current Lean efforts. Definitely recommended reading.


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Wednesday, May 07, 2008

LeanBlog Podcast #42 - Martin Hinckley, Mistake Proofing

This is LeanBlog Podcast episode #42 with Dr. C. Martin Hinckley, of the firm Assured Quality. He is the author of the book "Make No Mistake!: An Outcome-Based Approach to Mistake-Proofing," available through Productivity Press. We'll talk about his book and approaches for teaching people how to develop mistake proofing in processes.

For earlier episodes, visit the main Podcast page, which includes information on how to subscribe via RSS or via Apple iTunes.

You can use the player (use the VCR-type controls) below to listen to a "streaming" version of the podcast (or click here for the streaming audio and RSS subscription). The streaming link is faster for one-time listening (hardly any delay to start listening). Or you can use the download link to put it on your iPod or other MP3 player.




MP3 File Right-Click to "Save As"


LeanBlog Podcast #42 Key Points & Links

If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.


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Thursday, April 03, 2008

Inventor-itis, Not Inventory-itis

IndustryWeek Article about the Book | Subscribe to IndustryWeek

Amazon Link: Overcoming Inventoritis: The Silent Killer of Innovation

When I first read this headline, I misread it, thinking it was about the "fear of inventory" (something that seems like a Lean concept... not being sure how being afraid of inventory would kill innovation).

Turns out, the book's concept is that some companies fall in love with their products (the way an inventor might tend to do). This love for their product (or pride in their own inventing ability) can blind them to the market or to feedback - they cannot see the need for improvement. Interesting concept, but this portion stood out:
"Q: How does the Toyota Production System weed out Inventoritis?

A: Toyota's system is a consistent set of processes and principles applied over a long period of time. These 'lean' methods serve to reduce inventoritis and its downsides.

One aspect of the Toyota Production System is the idea of eliminating and not just reducing waste. In the traditional U.S. manufacturing system, the production line has slack built into it so that there is extra time and production line materials and resources available to ensure that the line stays running. In the Toyota system, there generally is not. There is obviously little or no tolerance for the waste that comes from people infected with inventoritis being able to influence the innovation process.

Toyota also has a very good knowledge management system. There are systems at the company for constructively gathering feedback from anyone and everyone throughout the organization, processing the information and applying it to the manufacturing process. Part of this stems from Toyota's deep respect for its people, one of the main pillars of the Toyota Production System."
I'm having trouble seeing the connection between what sounds like "inventory"-itis" in that second paragraph and the topic of the book. I think their main point about Toyota is that they have effective mechanisms for getting feedback from EVERYONE in the organization, not just executives. So maybe the idea is that Toyota is not in love with their production system in a way that blinds them to opportunities to improve?

One other quote from the author was interesting - he says you should "assume your product or idea is terrible." Toyota is often their own worst critic. Internally, the embrace the open discussion of ideas and problems, which is the first stage in problem solving and improvement. Most companies have a culture where problems are hidden and discussion is suppressed -- since making problems visible doesn't fit with their view that the company must be "perfect."

How do you interpret that article or the ties to Toyota and its production system or Lean?

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Review: Shingo's Kaizen and the Art of Creative Thinking

By Ralf Lippold, Leipzig Germany:

Kaizen and the Art of Creative Thinking - The Scientific Thinking Mechanism

How does it contribute to the lean knowledge base?

Shigeo Shingo offers a scientific way to get into Kaizen from a bundle of different perspectives in order to strive towards perfection. To achieve improvements through Kaizen, one often has to think "out of the box" and he embeds this perfectly in small stories that happened to him during his time as a consultant to various firms besides Toyota.

What are the highlights? What works?

Shigeo Shingo, at an early stage in history, talks implicitly about mental models that often hinder us from doing things in other ways we yet know of or used to do. Shingo slowly leads the reader through different stages of understanding where these mental models stem from and what they can result in (e.g. not solving the current pressing problems).

As the reader connects to Shingo's writing style and the connection with current reality while reading the book all of the little stories and anecdotes will make perfect sense.

As soon as the reader sees what Shingo is trying to accomplish, he will look for more personally experienced examples in his own work field and that is just what intended to happen. Further finding depend totally on the reader's creativity -and that's exactly what the whole book is about.

A great benefit towards other books on lean topics is the easy language in the told stories that can be easily shared through storytelling and therefore give way to easier connection with workforce.

What are the weaknesses? What's missing?

For readers who are used to more clearly structured -from their point of view- books on Lean or Kaizen will be probably a bit disturbed as the small anecdotes feel awkward as there is not always a straight connection to current reality. As one might suspect, this is totally done on purpose to propel new thinking in the reader's mind in order to find new solutions to common problems and -sometimes not yet- seen ones.

A shortcoming could be the diagrams covering the methodology of the analytical thinking as they are in a way disconnected from the rest of the writing.

How should I read this to get the most out of it?

The book can be read straight through - for a first run. After that initial reading a diving into specific sections in the book such as "Capturing Problems" or "Promoting Improvement Ideas" once in a while due to actual happening topics can be quite useful.

As learning begins with thinking and reflection about the told stories and how they apply to one's own work field it opens a wide field for discussion with colleagues and friends in order to unearth hidden mental models (personal assumptions due to experience) and open the gate to new learning.

Especially the last part of the book "Promoting Improvement Ideas" is extremely valuable for everyone concerned with change.

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Monday, March 31, 2008

LeanBlog Podcast #39 - Jeff Liker, Toyota Culture, Part 2

Here is LeanBlog Podcast #39, once again featuring Dr. Jeffrey Liker, Professor of Industrial and Operations Engineering at the University of Michigan. Dr. Liker is most recently the co-author (with Michael Hoseus) of Toyota Culture: The Heart and Soul of the Toyota Way and many other books, which can be found here on amazon.com. This is part 2 of what will be a 3-part podcast series, so be sure to check back. Today, we talk about some of the challenges that organizations face in trying to adopt a Lean Culture.

For earlier episodes, visit the main Podcast page, which includes information on how to subscribe via RSS or via Apple iTunes.

You can use the player (use the VCR-type controls) below to listen to a "streaming" version of the podcast (or click here for the streaming audio and RSS subscription). The streaming link is faster for one-time listening (hardly any delay to start listening). Or you can use the download link to put it on your iPod or other MP3 player.




MP3 File Right-Click to "Save As"

LeanBlog Podcast #39 Key Points & Links

  • Will Dr. Liker be writing more about companies who have gone through the Lean culture transformation, examples other than Toyota, ala his earlier book, Becoming Lean: Inside Stories of U.S. Manufacturers?

  • Bob Emiliani's book on Wiremold: Better Thinking, Better Results Case Study and Analysis of an Enterprise-Wide Lean Transformation

  • Why is it so hard to find examples of companies that have really adopted a Lean culture?

  • Thoughts on the impact of top American leaders departing Toyota (Jim Press and Gary Convis)

If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.


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Monday, March 10, 2008

LeanBlog Podcast #38 - Bob Emiliani, "Practical Lean Leadership"

Here is LeanBlog Podcast #38, our guest today is Bob Emiliani of the Center for Lean Business Management and, most recently, the author of Practical Lean Leadership: A Strategic Leadership Guide For Executives. It's a workbook-style guide that forces you to think through your own leadership approach and your own situation, a book I enjoyed very much. In this podcast, we talk about "lean leadership," "value added behaviors," and some pitfalls to avoid in lean implementations.

For earlier episodes, visit the main Podcast page, which includes information on how to subscribe via RSS or via Apple iTunes.

You can use the player (use the VCR-type controls) below to listen to a "streaming" version of the podcast (or click here for the streaming audio and RSS subscription). The streaming link is faster for one-time listening (hardly any delay to start listening). Or you can use the download link to put it on your iPod or other MP3 player.



MP3 File Right-Click to "Save As"


LeanBlog Podcast #38 Key Points & Key Words

  • How Bob first got involved with Lean and, especially, the leadership component.
  • What's different about this new Lean book?
  • What are some examples of "non-value-added" management activities or behaviors?
  • A definition of kaizen that emphasizes that kaizen cannot be sub-optimizing, you must look at the whole
  • Some errors to avoid in Lean implementation, avoiding "fake Lean"
    • If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.


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      Monday, March 03, 2008

      LeanBlog Podcast #37 - Jeff Liker, Toyota Culture, Part 1 of 3

      Here is LeanBlog Podcast #37, once again featuring Dr. Jeffrey Liker, Professor of Industrial and Operations Engineering at the University of Michigan. Dr. Liker is most recently the co-author (with Michael Hoseus) of Toyota Culture: The Heart and Soul of the Toyota Way and many other books, which can be found here on amazon.com. This is part 1 of what will be a 3-part podcast series, so be sure to check back.

      For earlier episodes, visit the main Podcast page, which includes information on how to subscribe via RSS or via Apple iTunes.

      You can use the player (use the VCR-type controls) below to listen to a "streaming" version of the podcast (or click here for the streaming audio and RSS subscription). The streaming link is faster for one-time listening (hardly any delay to start listening). Or you can use the download link to put it on your iPod or other MP3 player.




      MP3 File Right-Click to "Save As"


      LeanBlog Podcast #37 Key Points

      • Overview of the book, how it builds on the previous books.
      • The people part is such a foundation of the Toyota Way, had to expand upon it.
      • Looking at the cultural assumptions in the 14 principles.
      • In the book, seeing a "day in the life" of a Toyota supervisor.
      • Get a clearer picture of the "respect for people" principle throughout the book
      • Thoughts on implementing Lean the "wrong way."

      If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.



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      Monday, February 18, 2008

      More from Emiliani and Upcoming Podcast

      Superfactory - Article: The Equally Important "Respect for People" Principle by Bob Emiliani

      Here's a recent article from Bob that was hosted on superfactory.com about the Toyota Way principle of "Respect for People." It's a very well annotated history of writings and references about this oft-forgotten principle. If you're skeptical about the origins or importance of this principle, please check out his article. "Continuous improvement" is not the only important Toyota Way principle. "Continuous improvement" and "respect for people" are of equal importance, according to Toyota.

      From the article:
      Lean community leaders have recently made two huge changes in how they present Lean. The first change is Lean as a management system rather than “Lean manufacturing.” Second, they are finally taking note of the long-established “Respect for People” principle. Why now? In part because there have been so few successful Lean transformations over the last 20 years. Another reason is that most other aspects of the Lean management system have been studied in detail, so this is the next territory to explore. This batch-and-queue non-integrative approach has severely increased the lead-time needed to properly educate people about Lean management – particularly the “Respect for People” principle.
      I have a podcast interview with Bob scheduled for Saturday. If you have questions about that article or his most recent book, Practical Lean Leadership: A Strategic Leadership Guide For Executives, send me an email at leanpodcast [at] gmail [dot] com.

      You can listen to my previous podcast with Bob here.


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      Friday, February 08, 2008

      LeanBlog Podcast #36 - Norm Bodek on the new Shingo Book

      LeanBlog Podcast #36 once again features our friend and frequent guest, Norman Bodek, noted lean author, consultant, and President of PCS Press. In this episode, Norman talks about his most recent publication, a text by the legendary Shigeo Shingo, called Kaizen and the Art of Creative Thinking - The Scientific Thinking Mechanism, as well as future publications he is working on. This was recorded back in 2007, before the book was published (it has now been out in publication for a few months, I apologize for the delay in getting this podcast released).


      If you enjoy this podcast, I hope you'll check out the rest of the series by visiting the LeanBlog podcast main page.




      MP3 File (Right Click to Save-As)


      Keywords and Main Points, Episode #36

      If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.
      Click here for the main LeanBlog Podcast page with all previous episodes.



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      Saturday, January 26, 2008

      Starting to Read "Toyota Culture"

      I've read the first chapter of Toyota Culture: The Heart and Soul of the Toyota Way. I'm obviously not going to get through the whole thing before my podcast interview with Jeff Liker tomorrow. If you have questions for the podcast, let me know today.

      The first chapter provides a good overview and framework around the general question of "so what is a company or organizational culture?" Liker and his co-authors cover some of the aspects of what is "Toyota Culture" versus "Japanese Culture" and the influences that Japan has had on Toyota and how the culture has changed or adapted in the West.

      The authors are pretty blunt in their assessment that many companies are implementing Lean the wrong way -- with failure modes including:
      • Viewing Lean as a "toolkit"
      • Wanting central control, powerpoint reviews, and obsessive cost justification
      • Wanting to do Lean everywhere all at once instead of starting with a model line area
      There's also a great story from co-author Hoseus from his time working a line at Toyota in Japan. He created a small scratch inside a wheelwell and thought, "Maybe I could get away with that... should I pull the andon cord or not?" He pulled the cord, alerting the team leader of the problem. He not only got coaching on how to avoid that problem again (instead of getting yelled at), but the team members APPLAUDED him for admitting to a mistake. That sort of behavior is pretty rare among companies that are implementing the Lean tools without really focusing on their culture and behaviors.

      There's also some pretty blunt talk about the differences between Six Sigma and Lean. The authors say that the Six Sigma view of "Y = f (X)" is an overly simplistic view of work as consisting of a bunch of independent variables, instead of viewing a workplace as a complex system. I'm sorry to stoke the sometimes contentious debate about Six Sigma and Lean, but I'm curious to see if the authors talk about this more.

      There's a lot of great knowledge in this book for just $20.

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      Wednesday, January 23, 2008

      LeanBlog Podcast #34 -- Chris Harris, Lean Workforces

      LeanBlog Podcast #34 is a discussion with Chris Harris, from Harris Lean Systems, and co-author of the book Developing a Lean Workforce: A Guide for Human Resources, Plant Managers and Lean Coordinators. You can also purchase the book through Productivity Press.



      If you enjoy this podcast, I hope you'll check out the rest of the series by visiting the LeanBlog podcast main page. Now that my book manuscript is done, I'm going to get back into regular podcasting, with episodes in the coming weeks featuring Norman Bodek, David Meier, and Jeffrey Liker. Let me know if you have questions for Dr. Liker, using the contact info at the bottom of this post.




      MP3 File (Right Click to Save-As)


      Keywords and Main Points, Episode #34

      • Chris started working the assembly line at Toyota, then became a production supervisor at both Toyota and a different Tier 1 auto supplier.

      • Focusing on the people is key, assuming most people want to do a good job.

      • What's the proper role of a "Lean Coordinator"?
      • What's the right role for a supervisor or a team leader? How do you make that transition?
      • "The same reason Lean succeeds is the same reason it fails.... leadership."

      If you have feedback on the podcast, or any questions for me or my guests, you can email me at leanpodcast@gmail.com or you can call and leave a voicemail by calling the "Lean Line" at (817) 776-LEAN (817-776-5326) or contact me via Skype id "mgraban". Please give your location and your first name. Any comments (email or voicemail) might be used in follow ups to the podcast.

      Click here for the main LeanBlog Podcast page with all previous episodes.


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      Sunday, January 13, 2008

      "Toyota Culture" is Out

      Jeffrey Liker's new book on Toyota Culture: The Heart and Soul of the Toyota Way is out. I'm getting a copy on Tuesday and hope to post a review ASAP. If anyone else is reading it, feel free to share comments here.

      Update: I am recording a podcast interview with Dr. Liker on January 27. If you have questions for him, email me, or call the Lean Line to record an audio question. You can catch earlier discussions with him here and here.

      Maybe this should be "culture week" here on the blog. On Tuesday, I'm attending the Lean Enterprise Institute class on "Creating a Sustainable Lean Culture" here in Dallas (anyone else attending???)

      If anyone has stories to share about your own "lean culture" efforts, post a comment or email me using the link in left-hand column. Anything emailed to me will only be published with your express permission and I'll respect any needs for anonymity. Are you successfully transitioning to a "lean culture?" What are you struggling with?

      I've been fortunate to be working one hospital laboratory department, in particular, that is doing some really good work toward becoming more lean in their management approach and culture (kaizen, problem solving, and other lean methods). Maybe I can ask their director to share some thoughts on their experiences. Lots of good work going on in other hospitals too, that's very encouraging.




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      Thursday, January 10, 2008

      My Book is Done!

      Just an update for those who were following the progress of my book on "Lean Hospitals." It's done! I have submitted the manuscript to the publisher (Productivity Press, a division of Taylor & Francis).

      I'll provide updates on the publication status as we go and when it will be available. The working title has been "Lean Hospitals: Improving Quality, Patient Safety, and Employee Satisfaction," although that is subject to change. Part of me hates the description of any organization as "Lean" since Lean is more of a journey than a destination... but "Hospitals That Are On the Never Ending Continuous Improvement Journey"isn't real catchy. I do make the point in the book that nobody is never "Lean" as an end state, Lean describes the mindset and the methods.

      I have a website for the book at www.leanhospitalsbook.com. I hope to build an online community around the book, with a discussion forum and other interactive features (any ideas you have about that would be appreciated). One problem with writing a book is that it is a large "batch" of information that is, by nature, many months out of date by the time the book is available for sale. I'm hoping to provide additional case studies and updates on the hospitals mentioned in the book.

      The book is not intended as a detailed "how to" implementation guide. It is meant to be an overview that covers topics such as:
      • Why do hospitals need Lean?
      • What is Lean?
      • Case examples that show how hospitals are successfully using Lean
      • How to get started with Lean
      There is as much focus on leadership, culture change, and the Lean mindset, so that Lean is not just presented as a toolkit.

      Many thanks to those who asked about the book, provided encouragement, or reviewed some of the content.

      As I wrote in the preface, it really has been an honor and a privilege to have the chance to write this type of book. Let's hope it has a positive impact.

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      Friday, November 16, 2007

      Book Review: How Toyota Became #1

      Review By Mike Gardner, TPM Blog

      Name of the Book: How Toyota Became #1

      Author: David Magee

      Publication Date: 2007


      Book description:

      David Magee interviewed current and former Toyota executives in the United States and Japan in order to understand the Toyota Way straight from the people who live it every day. Toyota leaders such as Jim Press, Gary Convis, Mitsuo Kinoshita, and Koki Konishi spoke freely and honestly with Mr. Magee about the leadership philosophies that make Toyota work. The result is a nicely crafted synthesis of theory and practice. Chapter topics include such Toyota principles as kaizen; teaching employees to think; empowerment (pull the cord); understanding and serving the customer; and the power of paranoia.

      Each chapter includes examples of how Toyota has implemented their principles and a direct comparison to companies such as Ford and General Motors. These comparisons illustrate the differences between the companies and the results each achieved. The author allows the facts to speak for themselves, but occasionally interjects some personal opinions into the comparisons.

      How does it contribute to the lean knowledge base?

      This would be a good introduction for anyone interested in lean manufacturing or Toyota. This is not an in-depth analysis of Toyota’s management principles such as can be found in Jeffrey Liker’s The Toyota Way. Mr. Magee is a journalist, and he writes in a straightforward conversational style. Much of the book is based on his interviews with people within Toyota so it reads like an informal discussion. There is not a lot of hard analysis here, but there is a lot to learn about the pillars of lean that focus on people. Regardless of the chapter topic, the narrative usually concludes with the fact that the people are what make Toyota successful. The respect for and development of people has been the central tenet of all aspects of the Toyota Production System for almost sixty years.

      What are the highlights? What works?

      I found the conversational style and emphasis on interviews worked well together to create an engaging and informative narrative. Reading about Toyota’s philosophies and how they have been put into action directly from those responsible for them is much better than from an outsider’s perspective. There is a nice synthesis between the interviews, the history of Toyota, and the principles of the lean enterprise. The constant and direct comparison between Toyota and other automobile companies lends an important perspective to the story.

      What are the weaknesses? What’s missing?

      The biggest criticism I have of this book is the physical layout. I was taught that it was bad form to split words between two lines and it should only be done as a last resort. If a word had to be split, there were rules to be followed, such as splitting only words of three or more syllables and not splitting between the first and second syllables. This book was obviously typeset by a computer whose algorithm mandated and exactly straight right margin throughout. The result is that many words are split between lines that should not be. Often there are three or four lines in a row with split words. This can be very disconcerting to the reader. I had to make a conscious effort to ignore this and concentrate on the text.

      For the most part Mr. Magee allows the facts to speak for themselves, but he occasionally allows himself to descend into a little hyperbolic cheerleading for Toyota at the expense of other car companies. It does not happen very often, however, and he remains very objective otherwise.

      How can I get the most out of this book?

      This is a good book to read while traveling—I read it while on planes and in airports last week. It is not a textbook on lean implementation, but rather an interesting narrative about the success of Toyota and the people who have made the company the premier automotive manufacturer in the world. It is a great book for those just beginning the lean journey and also would make a good gift for those friends and relatives we all have who do not understand “this lean thing” we spend our lives on.

      The book can be purchased at amazon.com

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      Monday, November 12, 2007

      Norm Bodek on the new Shingo Book

      The following is a message from Norman Bodek, printed with his permission.

      -----------------------------

      Dear Lean Blog readers,

      Dr. Shingo was the co-discover of TPS/LEAN.

      A NEW SHIGEO SHINGO BOOK

      November 9, 2007 Vancouver, Washington

      Announcing a new hardcover Shigeo Shingo book, Kaizen and The Art of Creative Thinking - The Scientific Thinking Mechanism. Once again Dr. Shingo will amaze you. Along with Taiichi Ohno, Dr. Shingo co-developed TPS (LEAN) with his deep understanding of how to improve the overall process of production. Dr. Shingo reveals how he taught Toyota and other Japanese companies the art of identifying and solving problems.

      Many companies in the West are trying to emulate Lean but few can do it. Why not? Possibly, because we in the West do not recognize, develop and support the creative potential of every worker in solving problems. Toyota makes all employees problem solvers. Shingo gives you the tools to do it.

      It is an easy to read brilliant book!

      Dr. Shingo presents six unique models, the sum of which he calls the Scientific Thinking Mechanism. These frameworks allow groups to deconstruct problems and rebuild them into powerful improvement ideas. This concept is central to TPS and provides the necessary foundation for any Lean Initiative to be built upon.

      “Dr. Shingo was a master of Kaizen, he had the scientific training and innovative genius to deeply understand processes and the humility to realize that he needed the operators to take ownership. We are fortunate to have this new opportunity to gaze deeply into the thinking of one of the true geniuses behind TPS. —Dr. Shigeo Shingo.” – From the foreword by Jeffrey K. Liker, Ph. D., New York Times best-selling author of The Toyota Way

      “This book contains a myriad of case studies taken from office examples as well as shop floors. It is a gold mine of improvement ideas that cumulatively must have saved millions, and could still do so today!” Don Dewar, President & Founder, Quality Digest Magazine

      “Kaizen and the Art of Creative Thinking is a revealing book and is the genesis manuscript to the Lean Manufacturing mindset. It captures the fundamental thought process to structure problem solving activities and is the foundation to all essential aspects of the Kaizen philosophy. Truly a wealth of knowledge, wisdom and frameworks to embolden you to change existing practices!” - Michel Mestre, Ph.D. Professor, School of Business Northwest University

      “For those of us who have revered the work of Dr. Shingo, this is an exciting work. More so than any other of his books - Bill Kluck President, Northwest Lean Network

      “Practicing Kaizen (the habit of making small improvements) eludes many people. Dr. Shingo’s Scientific Thinking Mechanism replaces the hope of the flash of creativity with a reliable and learnable habit-building approach. Thanks for making this Rosetta Stone for kaizen available to the world.” - Hal Macomber Principal Lean Project Consulting, Inc.

      “This book teaches managers to be problem solvers instead of problem chasers.” – Collin McLoughlin, co-publisher

      Norman Bodek in 1979 started Productivity Inc.- Press and published hundreds of books on Toyota and Japanese management.

      The book retails for $59.40 and is available at www.enna.com

      Best wishes,

      Norman Bodek
      PCS Inc.


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      Friday, October 26, 2007

      New Shingo Book out Nov 1

      Kaizen & the Art of Creative Thinking: Enna

      I just had a nice conversation with Norman Bodek, which I'll be turning into a series of Podcast episodes as time allows.

      One exciting tidbit he shared with me is the publication of a previously-unpublished (in English, anyway) a new Shingo book. Norman was involved in the selection and the translation of the book, which is focused on identifying problems and problem solving.

      From the publisher's website:
      Kaizen and the Art of Creative Thinking is a newly discovered classic from Dr. Shigeo Shingo, the original Lean Manufacturing genius. Never before published in English, Kaizen and the Art of Creative Thinking provides the single most important tool for initiating a Lean transformation, Dr. Shingo’s own Scientific Thinking Mechanism. For the first time ever, you have access to Toyota’s secret model of success; learn how to dissect the status quo so you can address the actual problem, generate innovative ideas in group environments, and learn the best way to implement solutions. This book unlocks the secret to managing creative thinking.
      I don't see it on amazon.com, so you have to get it through the enna.com website (link at the top of this post).

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      Tuesday, October 23, 2007

      How Toyota Became #1, and Will Again

      I've mentioned this book before, coming out Nov 1, it's called How Toyota Became #1: Leadership Lessons from the World's Greatest Car Company.

      I had the exciting chance to have dinner tonight with the author, David Magee. I have, in my possession, four autographed copies of the book, courtesy of David. One is claimed by a Lean Blog reader who volunteered to do an early review (and I'm keeping one for myself so I can review it). I still need to think of a contest or a way to give away the other two books. Maybe a copy goes to someone who comes up with a reader contest idea!

      It's ironic and probably somewhat insignificant, in the big picture, that I got these copies on the day when headlines said "GM regains #1 position over Toyota" (link to a CNN article). That's probably a short-term blip rather than a wholesale shift in the industry, don't you think?

      Here are David's previous books(also available through amazon.com). Ignore the one on orthopedics, different author!

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      Friday, October 19, 2007

      How Curiosity Empowers Toyota

      Business Week Article

      Here is a new article from Business Week, which also focuses on the upcoming book How Toyota Became #1: Leadership Lessons from the World's Greatest Car Company.

      I'm going to have a chance to meet the author, David Magee, this week here in Texas. I should have a few copies of the book to give away, method TBD. I'm also hoping to do a Podcast with him if time allows.

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      Sunday, September 30, 2007

      Free Peeks into Taiichi Ohno's Book

      I think I've mentioned this resource before, the free content that is online in Google Books. Even though I own Taiichi Ohno's book Toyota Production System: Beyond Large-Scale Production, but it so much easier to search the book online.

      You can find major portions of the book here on Google Books, to read online. I'm not sure if the whole book is there, but there are certainly worthwhile snippets. Reading just a few of Ohno's words at the start of your work day may provide some great insight or inspiration. Check it out.

      If you find other books on there about Lean, post a comment or let me know. I only have a few titles in my Google "library" but I'll add more over time.

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