Synerflex Consulting

#1. The Toyota Way

How to speed up business processes, improve quality, and cut costs in any industry

In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors. The Toyota Way is the first book for a general audience that explains the management principles and business philosophy behind Toyota’s worldwide reputation for quality and reliability.

Complete with profiles of organizations that have successfully adopted Toyota’s principles, this book shows managers in every industry how to improve business processes by:

? Eliminating wasted time and resources
? Building quality into workplace systems
? Finding low-cost but reliable alternatives to expensive new technology
? Producing in small quantities
? Turning every employee into a quality control inspector

#2. The Toyota Way Field book

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota?s operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota?s success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures.

The book begins with a review of the principles of the Toyota Way through the 4Ps model?Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota?s lean systems will be provided with the inside knowledge they need to:

? Define the companies purpose and develop a long-term philosophy
? Create value streams with connected flow, standardized work, and level production
? Build a culture to stop and fix problems
? Develop leaders who promote and support the system
? Find and develop exceptional people and partners
? Learn the meaning of true root cause problem solving
? Lead the change process and transform the total enterprise

The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker?s extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.

#3. Lean Thinking

In the revised and updated edition of Lean Thinking: Banish Waste and Create Wealth in Your Corporation, authors James P. Womack and Daniel T. Jones provide a thoughtful expansion upon their value-based business system based on the Toyota model. Along the way they update their action plan in light of new research and the increasing globalization of manufacturing, and they revisit some of their key case studies (most of which still derive, however, from the automotive, aerospace, and other manufacturing industries).

The core of the lean model remains the same in the new edition. All businesses must define the “value” that they produce as the product that best suits customer needs. The leaders must then identify and clarify the “value stream,” the nexus of actions to bring the product through problems solving, information management, and physical transformation tasks. Next, “lean enterprise” lines up suppliers with this value stream. “Flow” traces the product across departments. “Pull” then activates the flow as the business re-orients towards the pull of the customer’s needs. Finally, with the company reengineered towards its core value in a flow process, the business re-orients towards “perfection,” rooting out all the remaining muda (Japanese for “waste”) in the system.

Despite the authors’ claims to “actionable principles for creating lasting value in any business during any business conditions,” the lean model is not demonstrated with broad applications in the service or retail industries. But those manager’s whose needs resonate with those described in the Lean Thinking case studies will find a host of practical guidelines for streamlining their processes and achieving manufacturing efficiencies. –Patrick O’Kelley (Amazon.com Review)

#4. Lean Solutions (Womack & Jones)

In Lean Thinking (1996), Womack and Jones expanded on the lean manufacturing model developed by Toyota to reduce waste and costs, reduce lead times, and improve quality. Here, they bring lean thinking to the broader world of consumer satisfaction. Traditional mass-consumption thinking has brought us tons of gee-whiz products but more frustration when it comes to actually getting what we want where and when we want it. Through a series of “consumption maps,” Womack and Jones highlight the “hassle time” inherent in the ways we shop, travel, and receive essential services, and then they offer novel ways for both consumers and providers to reduce this wasted time. We all know the dissatisfaction of going to the grocery store and finding the very item we need is out of stock. The new models reduce out-of-stock situations drastically by allowing consumers to dictate flow through demand rather than flow being driven by sales projections. Womack and Jones introduce ways to bring lean provision streams to some of our most hassle-laden consumer experiences, including the auto-repair, airline, and health-care industries. We can only hope someone is listening. (David Siegfried)

#5. The Machine That Changed The World: The Story of Lean Production

When The Machine That Changed the World was first published in 1990, Toyota was half the size of General Motors. Today Toyota is passing GM as the world’s largest auto maker and is the most consistently successful global enterprise of the past fifty years. This management classic was the first book to reveal Toyota’s lean production system that is the basis for its enduring success.

Now reissued with a new Foreword and Afterword, Machine contrasts two fundamentally different business systems — lean versus mass, two very different ways of thinking about how humans work together to create value. Based on the largest and most thorough study ever undertaken of any industry — MIT’s five-year, fourteen-country International Motor Vehicle Program — this book describes the entire managerial system of lean production.

Nearly twenty years ago, Womack, Jones, and Roos provided a comprehensive description of the entire lean system. They exhaustively documented its advantages over the mass production model pioneered by General Motors and predicted that lean production would eventually triumph. Indeed, they argued that it would triumph not just in manufacturing but in every value-creating activity from health care to retail to distribution.

Today The Machine That Changed the World provides enduring and essential guidance to managers and leaders in every industry seeking to transform traditional enterprises into exemplars of lean success.

#6. Creating a Lean Culture

Creating a Lean Culture helps lean leaders succeed in their personal batch-to-lean transformation. It provides a practical guide to implementing the missing links needed to sustain a lean implementation. Mann provides critical guidance on developing and using the key elements of a lean management system, including: leader standard work, visual controls, daily accountability processes, maintaining a process focus, managing key HR issues, and much more. In addition, a questionnaire is included to help assess current management practices and monitor progress.

Highlights: Distinguishes the much-discussed, abstract concept of “lean culture” from the concrete, implementable practices of lean management. Describes and illustrates 4 key principles of lean management: leader standard work; visual controls; daily accountability process, and discipline. Shows how visual controls bring process focus to life, tie in lean’s requirement for highly disciplined execution, and make leaders’ new jobs far easier to explain, model and evaluate. Moves beyond models and theories of lean management to show how to implement the daily practices that are the key to implementing and sustaining a lean transformation. Lots of case examples, figures and photographs.

#7. The Hitchhiker’s Guide to Lean

Hitchhikers do not travel a fixed path. They intentionally wander so they can learn and grow along the way. Embarking on the lean journey is similar, there are many roads on which to wander and no single one is right for all. “The Hitchhiker’s Guide to Lean: Lessons from the Road” reveals the most critical lessons learned over the authors’ combined 30-plus years of exploring the lean highways. One of the book’s lessons from the road is you need to pay attention to where you are and where you are going, just as you do when driving a car. Lean leaders add value by changing things, moving them forward, and producing different results than the day before. To lead, you must go beyond creating a vision. You must develop the vehicle that will deliver it. “The Hitchhiker’s Guide to Lean” is the vehicle that will help you move beyond the tools and take lean to a self-sustaining and continuously improving level. The book’s 10 chapters cover lean principles and thinking, lean leadership moves, the roadmap for lean transformation, common pitfalls of lean journeys, building an operating system, lean accounting, lean material management, lean in service organizations, and how individuals can apply lean to improve themselves. The book concludes with interviews of lean practitioners on the front lines of change at Chrysler, Ross Controls, DTE Energy, RSR Corporation, and Nemak.

#8. Toyota Product Development System (Morgan & Liker)

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.

In The Toyota Product Development System: Integrating People, Process, and Technology, James Morgan and Jeffrey Liker compare and contrast the world-class product development process of Toyota with that of a U.S. competitor. They use extensive examples from Toyota and the U.S. competitor to demonstrate value stream mapping as an extraordinarily powerful tool for continuous improvement.

Through examples and case studies, this book illustrates specific techniques and proven practices for dealing with challenges associated with product development, such as synchronizing multiple disciplines, multiple function workload leveling, compound process variation, effective technology integration, and knowledge management.

This valuable book:

Highlights the application of value stream mapping methodology to product development. Identifies and defines the categories of waste that are specific to the product development process. Presents countermeasures and proven practices, based on Lean principles, developed for the product development process used at Toyota. Illustrates and clarifies the methodology by presenting actual case examples at Toyota and a U.S. competitor.

Readers of this book can focus on optimizing the entire product development value stream rather than focus on a specific tool or technology for local improvements.

#9. Taiichi Ohno’s Workplace Management

This classic work by the founding father of the Toyota Production System returns to print in a new translation. Ohno delivers timeless lessons on how to effectively manage the gemba actual place or work. He relates stories from across his nearly 40 years of struggle to establish the Toyota Production System as both a mindset and supporting behaviors of constant improvement. In the book s 37 chapters, Ohno covers a broad range of topics and lays out the fundamental philosophy of kaizen (continuous improvement) that has made Toyota the most successful automobile manufacturer today.

#10. Andy & Me (Dennis)

Based on the author’s personal experience with Toyota senseis and with companies in the midst of great change, Andy & Me is a business novel set in a failing New Jersey auto plant focusing on the tribulations of Tom Pappas, the plant manager. The situations, characters and plant “politics” will ring true with many readers.

In a cool, readable style, Andy & Me follows Tom’s relationship with Andy Saito, a reclusive, retired Toyota guru whom Tom persuades to help save his plant through the “teaching” of legendary Toyota Production System (TPS).

On this journey, the reader learns that TPS is more than just a collection of tools; it entails a new way of thinking and behaving. Though Tom finds success ? both in his plant and in his personal life ? he learns from Andy that successful improvement is “endless and eternal.”