Recommended Books and Videos

Below is a list of books, videos and media that we would like to recommend.

Books

General Concepts

The Perfect Engine – Anand Sharma & Patricia Moody
For businesses, the time to make choices and fix outdated processes has come. Market speed and consumers demand it. Companies know how to build perfect systems, how to select and train and reward powerful, lifetime employees, and we know that selective and appropriate use of technology added to perfect process will produce the winners. Its’ a simple matter of execution.

The Machine That Changed the World - James Womack
Today, the industrial world is experiencing the most revolutionary change since Henry Ford's assembly line -- which forever changed the way things are made. Japanese companies are sweeping the world, as Western companies and governments struggle to find ways to emulate them.

Lean Thinking - James Womack and Daniel Jones
Expanded, updated, and more relevant than ever, this bestselling business classic by two internationally renowned management analysts describes a business system for the twenty-first century that supersedes the mass production system of Ford, the financial control system of Sloan, and the strategic system of Welch and GE. It is based on the Toyota (lean) model, which combines operational excellence with value-based strategies to produce steady growth through a wide range of economic conditions.

Toyota Production System: Beyond Large Scale Production - Taiichi Ohno
This volume represents the English translation of Ohno’s original commentaries, first published in Japan in 1978. More a philosophical commentary and history than an applications manual, it not only presents compelling examples of JIT implementation at Toyota, but also illustrates the mindset behind the system, especially the critical importance of teamwork and the premeditated effort to develop automation with a human touch.

Today and Tomorrow - Henry Ford
Originally published in 1926, Today and Tomorrow, written by the world's most famous automaker, Henry Ford, reveals the thinking that changed industry forever.

The Toyota Way – Jeffery Liker
In factories around the world, Toyota consistently makes the highest-quality cars with the fewest defects of any competing manufacturer, while using fewer man-hours, less on-hand inventory, and half the floor space of its competitors.

All I Needed To Know About Manufacturing I Learned In Joe’s Garage – William Miller & Vicki Schenk
A classic teaching fable valuable in all business functions. It is essential reading for anybody who wishes to understand how to succeed in today s environment of increasingly tough global competition. An annotated reading list and comprehensive glossary are provided.

Specific Tools and Techniques

Developing LeanSigma Leaders Workbook – TBM Consulting Group
Every lean company needs a steady supply of kaizen team leaders – individuals who will motivate, teach and guide their teams to success. The question for many organizations has been who will train the team leaders? Developing LeanSigma Leaders: A workbook for kaizen breakthrough team leadership is the answer.

Developing LeanSigma Leaders Pocket Guide – TBM Consulting Group
A companion guide to the workbook, the pocket guide includes all of the principles, tools, checklists and agendas of the original workbook, without the explanatory text and in a convenient size.

Handbook of Quality Tools: The Japanese Approach - Kazuo Ozeki & Tetsuichi Asaka
Accessible to everyone in your organization, the handbook includes information for both management and shop floor people; you'll find it an indispensable tool in quest for quality. The first part discusses management issues, roles, challenges, implementing improvements, process control, and leadership. As well, the second part is an in-depth discussion of each tool and its application.

The Kaizen Promotion Manual for Business Process – TBM Consulting Group
The Kaizen Promotion Manual for Business Process is designed for kaizen event coordinators, team leaders and those who supervise team leaders. This manual also serves as a guide for managers, vice presidents and others who will play an important part in the event planning, implementation and follow up. The manual provides guidelines on what to do before, during and after an event. It includes checklists in suggestions for implementation. The manual identifies potential implementation pitfalls and lists available resources.

The Kaizen Promotion Manual for Shop Floor Kaizen Breakthrough – TBM Consulting Group
The Kaizen Promotion Manual for Shop Floor Kaizen Breakthrough is designed for kaizen event coordinators, team leaders and those who supervise team leaders. This manual also serves as a guide for managers, vice presidents and others who will play an important part in the event planning, implementation and follow up. The manual provides guidelines on what to do before, during and after an event. It includes checklists in suggestions for implementation. The manual identifies potential implementation pitfalls and lists available resources.

Kanban: Just-In-Time at Toyota - Japan Management Association (Eds.)
Toyota's world-renowned success proves that with kanban, the Just-In-Time production system (JIT) makes most other manufacturing practices obsolete. This simple but powerful classic is based on seminars given by JIT creator Taiichi Ohno to introduce Toyota's own supplier companies to JIT. It shows how to implement the world's most efficient production system. A clear and complete introduction.

Learning to See, v. 1.3 – James Womack
Beginning with a forward by James Womack and Dan Jones, Learning to See breaks down the important concepts of value stream mapping into an easy to understand format. The manual, a Shingo Prize Winner, is filled with actual value stream maps, as well as engaging diagrams and illustrations.

Managing for Daily Improvement Workbook – TBM Consulting Group
Managing for Daily Improvement (MDI) is designed to provide the area leader with the tools and information that will make the job easier and the leader more effective. MDI is about getting control of your environment. TBM Consulting Group has developed this workbook to help you easily see the flow of work and material, potential safety and machine issues, and any deviation from standard work. Whether you have been leading for years or days, MDI will force some change in your habits. If you embrace that change, MDI will make your job easier and help you become a more effective manager.

A Revolution in Manufacturing: The SMED System - Shigeo Shingo
SMED (single-minute exchange of die)--or quick changeover techniques--is the single most powerful tool for just-in-time production. Written by the industrial engineer who developed SMED for Toyota, this book contains hundreds of illustrations and photographs, as well as twelve chapter-length case studies. Here are the most complete and detailed instructions available anywhere for transforming a manufacturing environment to speed up production and make small lot inventories feasible.

A Study of the Toyota Production System from an Industrial Engineering Viewpoint - Shigeo Shingo
Here is Dr. Shingo's classic industrial engineering rationale for the priority of process-based over operational improvements for manufacturing. He explains the basic mechanisms of the Toyota production system in a practical and simple way so that you can apply them in your own plant. This book clarifies the fundamental principles of JIT including leveling, standard work procedures, multi-machine handling, and more.

The Toyota Production System - Yasuhiro Monden
Toyota Production System, Third Edition, systematically describes the changes that have occurred to the most efficient production system in use today. Since the publication of the first edition in 1983, Toyota has integrated JIT with computer integrated manufacturing technology, a strategic information system, redesign of assembly lines, and a philosophy that incorporates respect for the workers. Even today, the goals of producing the necessary items, in the necessary quantity at the necessary time are the drivers of JIT. The addition of computer integrated technology, information systems technology, and changes that boost worker morale and improve working conditions serve to further reduce costs, improve quality, and improve cycle time. The Toyota production system considers how to adapt production schedules to the demand changes in the marketplace while satisfying the goals of low cost, high quality, timely delivery and improved worker morale.

TPM Development Program: Implementing Total Productive Maintenance - Seiichi Nakajima (Ed.)

Zero Quality Control: Source Inspection and the Poka-Yoke System - Shigeo Shingo
Dr. Shingo reveals his unique defect prevention system, which combines source inspection and poka-yoke (mistake-proofing) devices that provide instant feedback on errors before they can become defects. The result: 100 percent inspection that eliminates the need for SQC and produces defect-free products without fail. Includes 112 examples, most costing under $100.

Advanced Topics

The Antidote – Anand Sharma & Gary Hourselt
The Antidote is a one-stop guide to conducting business in the 21st Century and provides a roadmap for creating competitive advantage in the current global market place.

Real Numbers – Jean Cunningham and Orest Fiume
Are you getting a true picture of your company’s performance? The disturbing answer, for most senior managers and CFOs today, is no. The culprit? Current management accounting practices produce financial statements that are unnecessarily complex and confusing. As a result, most companies are run by executives who do not fully understand their own financial information. The authors of Real Numbers, each a chief financial executive in a pioneering lean company, describe how management accounting evolved to this point and how simplicity and clarity can be restored – particularly in a lean organization. Because you rely on your company’s financial information to make critical business decisions, Real Numbers is your next essential read.

Videos

Shingijutsu Jidoka
Available by contacting: KAIZEN Video Sales Section, SHINGIJUTSU CO., LTD., at: office@shingijutsu.co.jp - There are two different versions: Sheet Metal Fabrication and Machining Processes

Shingijutsu KaizenLecture Series
Available by contacting: KAIZEN Video Sales Section, SHINGIJUTSU CO., LTD., at: office@shingijutsu.co.jp

Time, The Next Dimension of Quality
Available from: CRM Films 800-421-0833 - Presents a methodology for analyzing business processes to eliminate waste.