Contents
Foreword
ix
Preface
xi
Acknowledgements
xiii
List
of abbreviations xvii
1 The business
of survival and growth 1
1.1 The new competitive
conditions 1
1.2 Silver bullets, initiative
fatigue and fashionable
management 3
1.3 Why programmes fail 4
1.4 The value of a compelling
vision 10
1.5 Leading the improvement
process 13
1.7 Summary: The foundation for a
better improvement
model 21
Bibliography 23
2 Lean TPM 24
2.1 Achieving the right balance
24
2.2 The origins of Lean Thinking
25
2.3 The origins of TPM 31
2.4 In summary, what does Lean
TPM offer? 36
2.5 Tackling the hidden waste
treasure map 37
2.6 The integrated route map 39
2.7 Summary 47
Bibliography 47
3 The change
mandate: A top-down/bottom-up partnership 49
3.1 The Lean change mandate 49
3.2 Changing the business model
53
3.3 The senior manager role 56
vi Contents
3.4 The middle/first line manager
role 68
3.5 Calculating the overall
equipment effectiveness 74
3.6 Shopfloor team 77
3.7 Summary 82
Bibliography 83
4 Transforming
the business model 85
4.1 Transformation and the
business model 85
4.2 The scope of the change
process 85
4.3 Change team roles 87
4.4 Setting and raising standards
89
4.5 Implementing ‘local’ policy
90
4.6 Operations team 92
4.7 Specialists 92
4.8 Facilitation 94
4.9 Summary 95
Bibliography 96
5 Process
stabilisation 97
5.1 Stabilising processes 97
5.2 The recipe for low inventory,
high flow and stable
operations 97
5.3 Setting work standards 104
5.4 Leading the implementation of
standards 107
5.5 Establishing operator asset
care 109
5.6 Understanding the voice of
the customer 110
5.7 Visualising the value stream
115
5.8 The process of stabilisation:
The free-flowing
materials map 119
5.9 Locking in the recipe for low
inventory, high flow
operation delivering zero
breakdowns and self-managed
teamwork 123
5.10 Summary 125
Bibliography 126
6 Process
optimisation 127
6.1 Introduction to the challenge
127
6.2 Changing drivers 128
6.3 Springing the strategy trap
134
Contents vii
6.4 Creating flexible
organisations 136
6.5 The optimisation process 137
6.6 Early Management (EM) 151
6.7 Capability development 156
6.8 Summary 161
Bibliography 163
7 Sustaining the
improvement drive 164
7.1 Introduction 164
7.2 Sustainability at the
management level 165
7.3 The operations level of
improvement 175
7.4 Summary 182
Bibliography 183
8 Conclusions
184
