Lean Production for Competitive Advantage: A Comprehensive Guide to Lean Methodologies and Management Practices, Second Edition introduces Lean philosophy and illustrates the effective application of Lean tools with real-world case studies. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, pull production, preventive maintenance, standard work, as well as synchronizing and scheduling Lean operations. Detailing the key principles and practices of Lean production, the text also:

  • Illustrates effective implementation techniques with case studies from a range of industries.
  • Includes questions and completed problems in each chapter.
  • Explains how to effectively partner with suppliers and employees to achieve productivity goals

Designed for students who have a basic foundation in production and operations management, the text provides a thorough understanding of the principles of Lean. It also offers practical know-how for implementing a culture of continuous improvement on the shop floor and in the office, creating a heightened sense of responsibility in all stakeholders, and enhancing productivity and efficiency to improve the bottom line.

In this second edition, the author addresses management’s role in Lean production. Early observers of Japanese methods focused on the shop floor to see amazing things unlike anything practiced elsewhere. And the thinking was, if the "methods" could be adopted by companies elsewhere, those companies would experience the success of the Japanese. What the early observers hadn’t considered were dramatic differences in the way those companies were managed, both daily and strategically. The "management side" of Lean production is addressed in two new chapters, one devoted to daily management, the other to strategy deployment. Additionally, there is a new chapter that addresses breakthrough improvement and an approach to achieving it called Production Preparation Process.

Every chapter has been revised and expanded to better tell the story of Lean production—its

history, applications, practices, and methods.

chapter |20 pages

Race without a Finish Line

part |97 pages

Continuous Improvement, Waste Elimination, Customer-Focused Quality

chapter |37 pages

Fundamentals of Continuous Improvement

chapter |35 pages

Value Added and Waste Elimination

chapter |21 pages

Customer-Focused Quality

part |263 pages

Elements of Lean Production

chapter |23 pages

Small Lot Production

chapter |26 pages

Setup-Time Reduction

chapter |37 pages

Maintaining and Improving Equipment

chapter |39 pages

Pull Production Systems

chapter |30 pages

Focused Factories and Group Technology

chapter |36 pages

Workcells and Cellular Manufacturing

chapter |23 pages

Standard Work

chapter |23 pages

Production Preparation Process, 3P

part |124 pages

Lean Production Planning, Control, and Supply Chains

chapter |38 pages

Uniform Flow and Mixed-Model Scheduling

chapter |21 pages

Synchronizing and Balancing the Process

chapter |26 pages

Planning and Control in Pull Production

chapter |36 pages

Lean Production in the Supply Chain

part |56 pages

Lean Management System

chapter |29 pages

Daily Management

chapter |24 pages

Strategy Deployment