Lean Thinking: Banish Waste and Create Wealth in Your Corporation

Charles L. Bradford reviews

by James T. Womack and Daniel T. Jones

Would you like to double productivity, cut development time by 60%, reduce inventory by 65%, reduce throughput time by 95%, reduce capital investment while doubling sales? Pre-existing assets, technologies, practices, organizations and concepts often cause enormous waste, i.e. activity which does not create value. This exciting book is about a way to do more and more with less and less - to create value instead of waste.

Lean Principles
1. Accurately understand VALUE (needs and preferences) from the customer’s perspective.

2. Perform VALUE STREAM analysis. This will reveal three types of actions: 1) those that create value, 2) those that do not create value but are unavoidable in the present situation and 3) those that don’t create value and are immediately avoidable.

3. After eliminating avoidable waste activities, make the remaining activities continuously FLOW. This requires the elimination of departmentalized “high speed” batch-and-queue “efficiency”. It requires quick changeovers, “right-sizing” and close coupling of operations without buffers. The authors state that the results are always a dramatic reduction of effort and improvement in throughput.

4. Because of the radical reduction achieved in throughput time, you now are capable of Just In Time operations. You can now let the customer PULL the product.

5. Finally search for PERFECTION. Perfection is, of course, impossible. But the effort compels progress.

“Just Do It”
The lean approach is to “just do it” with dedicated cross functional product teams which often include suppliers and customers.

The beauty of this system is that it won’t work at all unless everything works properly all the time. Thus 100% performance becomes an absolute requirement.

The authors present a number of very interesting case studies in which dramatic results were obtained. They conclude with advice as to how to get started - including a list of available resources.

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