Kindle Edition
Read instantly on your iPad, PC, Mac or Kindle Fire
Buy Price: $32.48
Rent From: $15.40
 
 
 
Sell Back Your Copy
For a $2.89 Gift Card
Trade in
Have one to sell? Sell yours here
Creating a Lean Culture: Tools to Sustain Lean Conversions
 
 

Creating a Lean Culture: Tools to Sustain Lean Conversions [Paperback]

David Mann (Author)
4.8 out of 5 stars  See all reviews (29 customer reviews)


Available from these sellers.


Textbook Student FREE Two-Day Shipping for students on millions of items. Learn more

Formats

Amazon Price New from Used from
 
Kindle Edition
Rent from
$32.48
$15.40
 
Paperback $34.19  
Paperback, May 13, 2005 --  
There is a newer edition of this item:
Creating a Lean Culture: Tools to Sustain Lean Conversions, Second Edition Creating a Lean Culture: Tools to Sustain Lean Conversions, Second Edition 4.8 out of 5 stars (29)
$34.19
In Stock.

Book Description

May 13, 2005 1563273225 978-1563273223 1
2006 SHINGO PRIZE for EXCELLENCE in MANUFACTURING RESEARCH

Lean production has been proven unbeatable in organizing production operations, yet the majority of attempts to implement lean end in disappointing results. The critical factor so often overlooked is that lean implementation requires day-to-day, hour-by-hour management practices and skills that leaders in conventional batch-and-queue environments are neither familiar nor comfortable with.

Creating a Lean Culture helps lean leaders succeed in their personal batch-to-lean transformation. It provides a practical guide to implementing the missing links needed to sustain a lean implementation.  Mann provides critical guidance on developing and using the key elements of a lean management system, including:  leader standard work, visual controls, daily accountability processes, maintaining a process focus, managing key HR issues, and much more.  In addition, a questionnaire is included to help assess current management practices and monitor progress.



Editorial Reviews

Review

"The new insights included in this second edition of Creating a Lean Culture, affirm our examiners recommendations in 2006 to recognize this original work with the Research and Professional Publication Award."
     —Robert D. Miller, Executive Director, The Shingo Prize for Operational Excellence

Praise for the First Edition

David Mann has provided an excellent review of one of the most common implementation issues in a lean transformation -- the essential day to day work practices of team leaders/supervisors/value stream managers that enable the lean system.
     -- George Koenigsaecker, President, Lean Investments, LLC

The purpose of lean systems is to make problems glaringly obvious. If implementation does not include standard leadership and cultural support systems to constantly address problems, the point of the system is missed. Many books address lean tools and initial conversion, but if you want the system to stick, read David's book.
     --Robert (Doc) Hall, Editor-In-Chief, Target, Association for Manufacturing Excellence

Mann's book is an excellent start toward Lean Leadership as 'process-dependent' rather than 'person-dependent' in style. The idea of leader standard work is simple and valuable.
     --Ross E. Robson, Executive Director, Shingo Prize for Excellence in Manufacturing

At last! A book that bridges the huge gap between the lofty visionary outcomes of Lean Leadership books - and the practical thinking and tools needed to put competitive outcomes in place. This practitioner approach spells out real work needed. All of us should use Mann's first five chapters to crystallize a 'Lean Management System' with the following five chapters to inspire us to roll up our sleeves.
     --David Hogg, P. Eng., President High Performance Solutions, Inc.


 

--This text refers to an alternate Paperback edition.

About the Author

David Mann is currently the principal of David Mann Lean Consulting. During a 21-year career with Steelcase, Mann developed and applied the concepts of a Lean management system. In his service with the company, he supported 40+ Lean value stream transformations, as well as developing and leading an internal team that completed over 100 successful office and product development Lean business process conversions.

Mann’s teaching and coaching experience includes Lean transformation in manufacturing, enterprise business processes, and healthcare organizations. His practice includes Lean and Lean management implementation in production and enterprise business processes, troubleshooting stalled Lean initiatives, as well as frequent training and speaking engagements on Lean management.

Mann is the author of Creating a Lean Culture: Tools to sustain Lean Conversions. Awarded the Shingo Prize in 2006, the book is now in its eighth printing, and is being translated into Chinese, Russian, and Thai.

Mann serves as a Shingo Prize examiner and assessor for the Honda Lean Network. He is a member of the Saint Mary’s Healthcare Lean Transformation Advisory Board in Grand Rapids, Michigan and is an invited contributor to Frontiers of Health Services Management. Mann is a frequent contributor to and member of the editorial board of the Association for Manufacturing Excellence’s publication Target, edits Target’s Single Point Lessons feature, and also serves on the board of AME’s Great Lakes Region. He is a faculty member in the Operations Management program at the Fisher College of Business, Ohio State University.

Mann is an organizational psychologist, earning his Ph.D. at the University of Michigan in 1976.

--This text refers to an alternate Paperback edition.

Product Details

  • Paperback: 224 pages
  • Publisher: Productivity Press; 1 edition (May 13, 2005)
  • Language: English
  • ISBN-10: 1563273225
  • ISBN-13: 978-1563273223
  • Product Dimensions: 10 x 7 x 0.5 inches
  • Shipping Weight: 13.6 ounces
  • Average Customer Review: 4.8 out of 5 stars  See all reviews (29 customer reviews)
  • Amazon Best Sellers Rank: #370,671 in Books (See Top 100 in Books)

More About the Author

Discover books, learn about writers, read author blogs, and more.

Customer Reviews

3 star
0
2 star
0
1 star
0
Most Helpful Customer Reviews
33 of 33 people found the following review helpful
Format:Paperback|Amazon Verified Purchase
One of the chronic problems to successfully implement and sustain a lean initiative is the confusion of management's role--how to be engaged and support beyond funding and verbal endorsement of a lean initiative. Surveys show a 56% success rate with lean. There is a crying need for a guideline for management to be aligned with the floor changes at ALL levels of management. This is key to developing a lean culture. The reason I like Mann's book is that he touches on things that aren't found elsewhere to developing a LEAN MANAGEMENT SYSTEM. Companies typically will hire consultants in hopes of taking them to lean nirvana. But, for most orgs, there are two components that could hurt you: the recalcitrant manager (typically 15-20%) and the rest of the organization that want to be engaged but don't know their role. Both could doom your efforts. Mann's provides an excellent prescription to help you get management realigned with standard roles and specific daily tasks at all levels. Without this, you're dead. I only wish his book was better written to facilitate application. The content is practical but the format isn't--more visuals are needed and a too wordy--but, the goods are definitely there. You won't be disappointed; I still highly recommend this book. If you are looking for some guidelines for conducting a Gemba walk or developing an assessment (don't miss his Appendix) he goes into great detail. The book is divided into two major sections:

What is the Lean Management System?

Ch 1: The Missing Link in Lean

Ch 2: The Lean Management System's Principle Elements

Ch 3: Standard Work for Leaders

Ch 4: Visual Controls

Ch 5: Daily Accountability Process

Learning Lean Management & Production: Supporting Elements

Ch 6: Learning Lean Mgmt: Sensei and Gemba Walks

Ch 7: Leading a Lean Operation

Ch 8: Solving Problems & Improving Processes--Rapidly

Ch 9: People--Predictable Interruption; Source of Ideas

Ch 10: Sustain What you Implement

Appendix, Glossary, References, Index.
Comment | 
Was this review helpful to you?
31 of 31 people found the following review helpful
By M and G
Format:Paperback
I've been doing Lean since 2000 (Six Sigma earlier, 1997) and have been applying general Toyota methods with what I'd consider a very good amount of success. The problem has been, how do you convey the necessity of the Toyota Lean method as a complete "business system" as opposed to JIT and "tools" thinking for busy, batch-thinking individuals? This book fills the gaping void.

Pro:
-Straight forward principles, complete and thorough
-Appear to be true to the Toyota principles as I have seen demonstrated by ex-Toyota executives/leaders turned consultants
-Drives to the heart of lean as a business system, with many elements that I've personally tried or seen work well
-A Shingo Prize winner... impressive
-Avoids excessive Japanese terminology (not an issue for me, but sometimes an issue for others)

Con:
-I think that the power of IT applications is somewhat understated, and pitfalls of using or attempting to use IT-related systems not well described. Would like to see a better description of pitfalls and issues more specifically. Until then, think of IT as you would if you were automating a process... it had better be high volume and well understood/mature.

Bottom Line: I think this a must-have text, and it is excellently written and laid out... plus it's to the point reinforced with numerous short case study examples. I'd recommend pairing this book with "The Toyota Way" (read that first to pave the way for this book). Also consider "The Toyota Way Fieldbook" as the ideal 3rd text to study. A word of caution, these books require a whole new way of thinking and commitment.
Comment | 
Was this review helpful to you?
15 of 15 people found the following review helpful
Format:Paperback|Amazon Verified Purchase
This is a fantastic book, one of the small number of "core" lean books that I recommend to people. I've used the book with many healthcare clients who are new to lean. They have loved the book so much that they have read it three times, learning something new each time, and learning something different at each stage of their lean learning journey. The most frequent comment I hear is that the book means one thing to them before they start but it means even more to them after they have "struggled" with a lean environment on their own, revisiting the book and its concepts helps immensely.

Mann's book helps make concrete the vague notion of a "lean culture" and spells out steps leaders can take to start moving in that direction. The book doesn't promise quick fixes, nor should it, but it puts you on the right path to developing your people, your leaders, and your problem solving skills. Kudos to David Mann for a very practical, actionable guide for lean leaders or those of us who strive to become lean leaders.
Comment | 
Was this review helpful to you?
Most Recent Customer Reviews
Good, practible guide for visual management
Good, hands on guide on implementation of visual management lean manufacturing. Have not found any
other guide this usable and practable
Published 4 months ago by Paul E. Hyde
Lean Culture - foundation of improvement
This is one of the best books to understand and implement a Lean Culture.
Very useful in our Quality & Environmental Systems.
Highly recommended.
Published 5 months ago by Gabriel Mejia
Clear, clean, and simple guidance
Good for any leader trying to maintain results, after the company lean experts are long gone. This book takes a performance management approach and is filled with good stories... Read more
Published 6 months ago by D. Taylor Davis
Great condition, great service
This book came in mint condition and very promptly, I have had great luck with purchases through Amazon and this was another good experience!
Published 8 months ago by cburnham
Having trouble sustaining lean improvements?
How many times have you found yourself holding repeat kaizen activity for the same problems? Are you losing ground on excellent work that everyone was excited about two months ago,... Read more
Published 10 months ago by Brian Hatcher
Completely satisfied
My order was shipped and delivered promptly. The book was in as new condition and I was VERY PLEASED with the price. Could not ask for better!!! Read more
Published 11 months ago by Mary Sue
Great book
An excellent and well written book. The writer understands how to apply lean tools to a realistic low volume high mix environment. Read more
Published 14 months ago by B. Scheiner
Admin. Assistant
We have found this book to be very helpful in our plant. Everyone should read it. If you are starting Lean in your business this is a great book.
Published 17 months ago by Kay
Creating a Lean Culture - David Mann
Creating a Lean Culture by David Mann was recommended to me by a senior manager at Toyota in the USA in response to our conversation about sustaining Lean in the long term,... Read more
Published on May 18, 2010 by Douglas Parker
Tools to address the human element of Lean
How to create and sustain a Lean culture, by addressing the "softer" aspects in a way to make the new methods stick. Read more
Published on May 6, 2010 by Scott
Search Customer Reviews
Only search this product's reviews

Inside This Book (learn more)
First Sentence:
Most prescriptions for lean production are missing a critical ingredient: a lean management system to sustain it. Read the first page
Key Phrases - Statistically Improbable Phrases (SIPs): (learn more)
project implementation, leader standard work, daily accountability process, gemba walking, vacation paradox, standard work for leaders, lean management system, value stream manager, lean sensei, value stream leader, attendance matrix, lean conversion, standard work documents, lean culture, support group representatives, daily task assignments, flow interrupters, lean leader, lean implementation, lean journey, disciplined adherence, standardized work, lean area, takt time, tracking charts
Key Phrases - Capitalized Phrases (CAPs): (learn more)
Rensis Likert
New!
Concordance | Text Stats
Browse Sample Pages:
Front Cover | Table of Contents | First Pages | Index | Back Cover | Surprise Me!
Search Inside This Book:



Tags Customers Associate with This Product

 (What's this?)
Click on a tag to find related items, discussions, and people.
 
(8)

Your tags: Add your first tag
 

Customer Discussions

This product's forum
Discussion Replies Latest Post
No discussions yet

Ask questions, Share opinions, Gain insight
Start a new discussion
Topic:
First post:
Prompts for sign-in
 


Active discussions in related forums
Search Customer Discussions
Search all Amazon discussions
   
Related forums



So You'd Like to...



Look for Similar Items by Category


Look for Similar Items by Subject