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Building upon the international bestselling Toyota Way series of books by Jeffrey Liker, The Toyota Way to Continuous Improvement looks critically at lean deployments and identifies the root causes of why most of them fail. The book is organized into three major sections outlining:
Section One: Using the Plan-Do-Check-Adjust (PDCA) methodology, Liker and Franz contrast true PDCA thinking to that of the popular, superficial approach of copying "lean solutions." They describe the importance of developing people and show how the Toyota Way principles support and drive continuous improvement. Explaining how lean systems and processes start with a purpose that provides a true north direction for all activities, they wrap up this section by examining the glaring differences between building a system of people, processes, and problem- solving that is truly lean versus that of simply trying to "lean out" a process.
Section Two: This section brings together seven case studies as told by the sensei who led the transformation efforts. The companies range from traditional manufacturers, overhaul and maintenance of submarines, nuclear fuel rod production, health care providers, pathology labs, and product development. Each of these industries is different but the approaches used were remarkably similar.
Section Three: Beginning with a composite story describing a company in its early days of lean implementation, this section describes what went right and wrong during the initial implementation efforts. The authors bring to light some of the difficulties the sensei faces, such as bureaucracies, closed-minded mechanical thinking, and the challenges of developing lean coaches who can facilitate real change. They address the question: Which is better, slow and deep organic deployment or fast and broad mechanistic deployment? The answer may surprise you. The book ends with a discussion on how to make continuous improvement a way of life at your company and the role of leadership in any lean transformation.
The Toyota Way to Continuous Improvement is required reading for anyone seeking to transcend his or her tools-based approach and truly embrace a culture of continuous improvement.
- Sales Rank: #268396 in Books
- Published on: 2011-05-10
- Original language: English
- Number of items: 1
- Dimensions: 9.30" h x 1.44" w x 6.40" l, 1.80 pounds
- Binding: Hardcover
- 480 pages
About the Author
Jeffrey K. Liker, the author of the bestselling The Toyota Way, is professor of Industrial and Operations Engineering and cofounder and cofounder and President of The Toyota Way Academy. With nine Shingo Prizes for research excellence his work has appeared in The Harvard Business Review, Sloan Management Review, and other leading publications.
James K. Franz learned lean as a Toyota Production Engineer in Japan, and has more than 22 years of manufacturing experience.
Most helpful customer reviews
5 of 5 people found the following review helpful.
The Value is the Case Studies
By Andy Evans
Section 1: The Journey to Continuous Improvement (p1-96) - Mostly a rehash of the authors earlier work and a little tedious. But press on!
Section 2: Case Studies (p97-342) - A very good series of warts and all case studies from US, Japan and Australia, written by a group of contributors. While not all in a factory production environment, they do tend to be in similar areas (ship repair: high volume valve overhaul shop, health care: path lab, nuclear: fuel can manufacture, resource industry: mining site). Many comments contrast mechanistic 6 sigma with the organic lean approach the authors take.
Section 3: Making your Vision a Reality (p343-432) - useful practical application material, useful for companies planning a lean transition and for budding consultants.
The authors do have certain views as consultants that not all readers will agree with but the book has value for anyone aiming for continuous improvement or planning a major cultural or organisational change.
4 of 4 people found the following review helpful.
Best Lean Book Ever Written
By Wally
I'm 'into' Lean Manufacturing, so for me this book was like Tom Clancy or Dan Brown. I couldn't put it down. For someone who doesn't find rapid change-over or manufacturing theories and philosophies quite so rivetting, this book might not be as 'fun' as a novel, but you'll still learn a great deal.
More importantly, this book is probably the best in terms of showing lean for what it really is - a business philosophy. Lean can be applied to anything, but it's not about specific tools and techniques so much as specific approaches to problem-solving and a commitment to improving continiously.
The Toyota Way shows how Lean evolved and in doing shows how one can evolve the principals of the underlying philosophies into their environment. Other lean books tend to focus more on the specific manufacturing toolsets. The truth is that if you adopt a lean culture, you'll stumble on the right toolsets over time even if you don't do so intentionally. If on the other hand you view lean as a set of tools to copy - as most American companies view it - you might get a few unsustainable short-term gains but you'll get little else. This is probably the best book at showcasing and selling lean as a culture and a philosophy. And it's awfully well written!
8 of 10 people found the following review helpful.
CI beyond Toyota
By Lean Learner
This is a great book to go deeper into understanding the key process of Toyota's success, PDCA. What I like about the book is that it not only gives the perspective from Toyota's point of view, but also from others. Well over half of the book is made up of "Case Studies", from other organizations and industries that helps me to apply these principles in other settings than just making automobiles. I highly recommend this book to anyone going through their "lean transformation".
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