Customer Reviews

The Kaizen Revolution

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Mr. Regan presents an easy read in novel form (ala "The Goal" by Elyahu Goldratt) giving the reader a sound introduction to the Toyota Production System (aka Lean Manufacturing). Anyone reading this book can gain a sound understanding of what steps to take, and why to take them, as you begin on the Lean journey. You'll close the back cover with an understanding of many "Lean Concepts" as well as a very sound introduction to the how and why's of preparing for and conducting a Kaizen event. The chapter summaries are very beneficial in helping you capture the nuggets of knowledge that you can easily overlook as you become engrossed in the story. Don't let this book be your only source of knowledge on TPS, but be sure to include it in your reading.

Finally a book that makes Lean Manufacturing simple, like it should be, and utilizes Kiazen's as a process instead of a series of events. The story-like approach to instructing the principles of Lean Manufacturing and the simplified approach to the use of Kiazen will make this book a must read for all level of a manufacturing organization.

I shared this book with others in my organization and immediately they desired to get started. Any book that helps break down the resistance to Lean Manufacturing concepts and shows you how to engage your workforce and their leadership in this common goal is a winner. I highly recommend this to anyone that is struggling with implementing Lean Manufacturing in their facility.

I have about 4 years experience using and implementing many of the lean ideas and techniques described in Mr. Regan's book. I recently started a new job where one of my missions was to implement "lean manufacturing" in the facility. I have often struggled to describe the "event" tool and have had to resort to telling folks "you'll understand it when you do it." Mr. Regan's book is another tool in my personal tool box to use to effectively outline the "event" process before I throw a group of folks into one. "The Kaizen Revolution"'s narrative style is easy to read and is therefore effective for any and all levels of the organization. This is a must read for organizations considering a move to lean or are just starting one.

Michael Regan writes his methodology of lean Kaizen methodology into a novel form. I have never really been fond of the novel approach to explaining business concepts. I feel like I just have to strip away the story and get to the facts. Which for some reason in my case becomes more more work for less results. But I can understand how that genre works for some.

Concepts that I found interesting

In value added versus non-value added tasks work is transformed. More precisely he uses the definition "A process step is value added if it causes a change in the physical state of the material in accordance to customer specifications" Waiting and moving are not transforming the work. Hence not value added in and of themselves.

The approach here is to make a value analysis

1) make a list of the process steps

2) determine value added and time elapsed

Note: Each process step is an opportunity to make mistakes and every step induces costs. Don't try to do things faster, instead try to eliminate process steps.

Regan also list the common ingredients to all similar lean methodologies

1) Just in time production

2) Continious one-piece flow (a product never stops moving until it is a finished product and there is no place for problems to hide)

3) Work cells

4) Reduction of Set Up Time

5) Preventative Maintenance

6) Kanban

7) Work place organization and cleanliness (also known as 5S, Sort, Straighten, Scrub, Schedule, Score ie Measure through visual management) Making it a daily ritual. Do not have material in your work place that you are not using and also have everything it is place.

8) Standard Work (Here the concept is about creating documentation so that a typical person in that role can pick it up and do that task. Fit on one side of one piece of paper.

9) Team of employess who think and take initiative

Another interesting concept is how underlying trust is important because we are asking people to transform their own job, a possibily to hopefully eliminate it.

In the appendix he includes a idea generating tips.

I especially appreciated

1) Give people a reason to think of improvement ideas

2) Supervisors stop reacting and solving problems rather lead

3) Problems are like elephants.... best to eat them one bite at a time.

5) Take time for reflection i.e. Lessons Learned

6) Have people cross trained.

Thanks for the listen. Happy Reading!

Great theory, but lacks applicability. Recommended reading for those contemplating using Kaizen in the workplace. Needs to be balanced out by reading a How-to-do-it book, such as the "Kaizen Event Implementation Manual", which does help you actually conduct a perfect Kaizen event.

This book is a fast read and a good introduction to Lean and the Kaizen Event. It covers all of the basics and enough detail to present a sound and solid beginning to anyone looking to understand Lean and Kaizen. If you are looking for solid meat beyond the basics, you need to go elsewhere. The book points you to other sources through out the text.

This book helped me understand what Kaizen is, how to get prepared for Kaizen event, what happens during Kaizen event, and what are the benefits of applying Kaizen in a company. This book is written in form of a fictional story, and walks you through Kaizen. I am using this book in a Kaizen event that I am currently leading.

This book was assigned as part of a manufacturing engineering course and I have recommended it to several co-workers. It's an easy read that teaches the basics of lean without having to dig through a textbook. Chapter summaries are a good reinforcement of the main points. This book would be a good asset for a team as basic research before implementing lean.

The Kaizen Revolution is a good basic book on the implementation of the lean manufacturing process to improve quality and reduce cost as well as eliminating waste (muda) and inefficiency. The Kaizen method of continuous improvement is a Japanese management concept that focuses on gradual, incremental change. It is an improvement philosophy that assumes that every aspect in a production system needs to be constantly improved. The book explains how to prepare for Kaizen event, what happens during the event as well as the benefits of applying the concept to an organisation. Continuous improvement and lean manufacturing are modern management tools that show the benefits of gradual, incremental changes rather than radical changes.

The book is written in the form of a story where it tales the reader through the Kaizen concept. This makes the book easy to read, follow and understand. All the essential basics are covered which gives the reader a strong foundation about what the Toyota Production System or lean manufacturing entails.

This is good basic reading for people wishing to understand lean manufacturing concept. However, those seeking a deeper understanding of the subject need to consult other books such as "Kaizen: The Key to Japan's Competitive Success by Masaaki Imai" or the "Kaizen Event Implementation Manual".