Relentless Improvement : True Stories of Lean Transformations

Tracing the author’s professional continuous-improvement journey, this book details successful Lean Six Sigma transformations to illustrate operational tactics. Starting out with very basic projects such as applying 5S, shortening product cycle times, and creating standard work, it then progresses to factory Lean Six Sigma transformations. The complexity and detail of the projects grow chapter by chapter. The text also contains accounts of "front end" or administrative processes such as product development or materials handling.

Tracing the author’s decades-long continuous improvement journey, Relentless Improvement: True Stories of Lean Transformations walks readers through vivid shop floor experiences to convey a genuine feel for the environments in which Lean Six Sigma transformations occur. Recounting numerous Lean Six Sigma transformations, it illustrates the spectrum of successful operational tactics.

The story starts just outside Detroit, Michigan in the 1970s when the auto industry was booming, and most people in the area worked in the car factories, or in one of the component factories that supplied the Big Three. The complexity and detail of the projects grow chapter by chapter. The book begins by explaining how to manage Lean basics such as applying 5S, shortening product cycle times, and creating standard work. It then progresses to factory Lean Six Sigma transformations. Providing implementation guidance geared to functions on the operational level, the book:

• Presents stories based on the author’s interactions with company leaders and shop-floor employees in the midst of great change
• Illustrates real-world plant politics and manufacturing situations using compelling stories
• Highlights valuable lessons learned at the end of each chapter

Using an engaging story format, the book recounts the author’s career experiences to provide you with a real-world understanding of how to use Lean tools. The stories in the book illustrate everything from standard work and takt time to Kaizen events and Total Productive Maintenance. The text also includes accounts of "front end" or administrative processes such as product development and materials handling.