Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer [Hardcover]

Dennis P. Hobbs (Author)

Book Description

ISBN-10: 1932159142 | ISBN-13: 978-1932159141 | Publication Date: October 2003

The proven, objective, standardized, and complete "how to" sequential series of progressive steps to Lean manufacturing implementation illustrated in this manual are easy to understand and use to effect factory transformation to lean without the aid of a consultant. It also provides a toolbox of techniques for problem - solving, continuous improvement, and for operating a Lean manufacturing facility on a day-to-day basis after the initial line design is completed

Editorial Reviews

From the Author

By now, most people interested in Lean manufacturing understand the fundamentals of Lean. The reason people can relate to the tenets of Lean is because they just make so much sense!  In fact, contrary to what some consultants will tell you, there are really no secrets to Lean. In one way or another, most of the techniques of Lean have been well known to manufacturers for years while using another name. However, a complete Lean transformation relies on all of these techniques working concurrently with one another to realize the full benefit of a Lean operating system. What has been missing is a consistent implementation methodology for making the conversion to a Lean operating system.  I wrote this book to help companies implement a Lean manufacturing system in their company without the aid of a consultant.  Now, this business model may seem like death for a Lean consultant's business. Instead, I believe the value added proposition of a consultant is not in the reading of the Japanese glossary or the extolling the benefits of Lean to you, but leveraging my experience and project management skills with Lean transformations to make your company's transformation project as efficient as possible with as little time wasted through trial and error or going down blind alleys. An experienced Lean consultant can help your company begin to enjoy the benefits of Lean months faster than your internal staff who usually have to baby step their way to implementation.

About the Author

Dennis Hobbs, CPIM, is a Principal Member of Mfg Matters, LLC, a boutique consulting firm that specializes in the training of Lean methods and performing Lean manufacturing implementations. He has over 30 years of combined line and staff experience in manufacturing, primarily in the field of production planning, inventory control, and materials management. Dennis has successfully implemented the installation of Lean manufacturing systems for numerous manufacturers around the world. Lean Manufacturing Implementation is Dennis' first book and was written to teach manufacturers how to implement the techniques of Lean manufacturing using their own internal staff.  As a professional instructor, he has trained over 2500 manufacturing professionals in Lean manufacturing techniques throughout the world, has published numerous articles, and is a sought-after speaker.

Product Details

• Hardcover: 280 pages
• Publisher: J. Ross Publishing, Inc. (October 2003)
• Language: English
• ISBN-10: 1932159142
• ISBN-13: 978-1932159141
• Product Dimensions: 9.3 x 6.2 x 0.8 inches
• Shipping Weight: 1 pounds (View shipping rates and policies)
• Average Customer Review: 3.5 out of 5 stars  See all reviews (8 customer reviews)
• Amazon Best Sellers Rank: #789,502 in Books (See Top 100 in Books)

More About the Author

Dennis P. Hobbs, born 1947. Dennis began his career in 1969 after serving in the US Army as a medical laboratory technician in a general hospital unit. His first job in manufacturing was as a "master scheduler" in 1972. The company produced vending machines and as he found out later, was one of the first companies to implement an MRP system. In 1974 he began working at a pharmaceutical company in Kansas City Mo. Over the next 18 years, this company implemented and operated two different MRP systems. Because he served in a Material Management capacity, Dennis was actively involved in the implementation projects and later their day-to-day operation. Dennis became very proficient in the operation of these MRP systems, but as time went on, became even more discouraged with the rigidity and lack of real time visibility these systems provided. Beginning in the 1980's more and more information became available about JIT, Re-Engineering and Flow manufacturing methods. Fascinated with these technologies, Dennis began a consulting career in 1994 with a firm implementing "Flow" manufacturing systems. This experience was an epiphany for Dennis transcending all he had learned about manufacturing up to this point. Often,consulting companies treated these methodologies as proprietary secrets while Dennis has always felt these techniques were "public domain" and should be used for the betterment of all society. To fulfill that calling, Dennis has written two books sharing his personal experiences along with the methods he has used for transforming companies into Lean operating systems.

Customer Reviews

Most Helpful Customer Reviews

50 of 53 people found the following review helpful:

1.0 out of 5 stars From a Lean Manufacturing Engineer, December 3, 2004

By 

Lean Manufacturing Engineer "Ron" (Overland Park, KS USA) - See all my reviews

This review is from: Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer (Hardcover)

This treatment of Lean Manufacturing is written from the American Production and Inventory Control Society (APICS) viewpoint. The center of the manufacturing world for the production control dept. is the MRP software which makes this viewpoint on Lean interesting, especially since two of the major advantages of implementing Lean is to reduce inventories and to eliminate production control department overhead. The only requirements for MRP in a lean environment are long term raw material scheduling and finished product delivery scheduling.
Hobbs does not establish the roots of Lean (The Toyota Production System) nor does he use Japanese lean terms with the exeption of Kanban and Kaizen. Nor does he recognize the existence of the value stream map (VSM) choosing to use the process flow diagram (PFD) to define the manufacturing process. Thus Hobbs only defines process level manufacturing data and totally ignores the systems approach to lean Manufacturing. As a result the Lean Enterprise, total lead time, and how the manufacturing process relates to the whole value stream are not even adddressed. He is, however, quick to use total lead time in his so called 'Strategic Business Analysis'. Finally, the key concept of pull/flow production control is not fully compared to push/MRP production control. Herein lies the proof that pull/flow is superior.
This is the only treatment of lean manufacturing I have found that espouses providing for scrap and rework in the manufacturing process. There is no jidoka even mentioned.
Somehow the term 'MRP' shows up on almost every page. This book should be labeled 'In Defense of MRP'.
There is no bibliography - all original?

1) A lean practitioners publication 2/10
2) A lean managers publicaton 4/10
3) Clear thought/Organization 3/10
4) Information Content 2/10
5) New or original content 2/10
6) Topical relevance 2/10

14 of 16 people found the following review helpful:

5.0 out of 5 stars Excellent How-To Guide, January 9, 2004

By 

"brockton808" (San Jose, CA United States) - See all my reviews

This review is from: Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer (Hardcover)

I have been looking long and hard for a simple, step-by-step guide to implementing Lean methodologies in my facility and I have finally found it. Most of the Lean books I've seen up to this point discuss high-level concepts, without detailing the steps and tools needed to put the strategy into practice. However, this book (more of a "how-to" manual, really) outlines all the tasks needed to move from a traditional batch manufacturing system to a Lean environment.

It covers everything from project scoping to line design to Kanban materials movement systems. Not only that, the author provides all the tools (formulas, charts, project management tips, etc.) to guide you through the process. He's also provided methods, like the daily resource planning tool, that help you manage the line after the Lean processes are up and running.

I'm using the guide now for my line reconfiguration, and have gotten it for everyone on my implementation team. This book is good for any manufacturer that is planning to implement Lean, but doesn't have a plan for how to go about it.

Highly recommended!

11 of 13 people found the following review helpful:

5.0 out of 5 stars Finally! A Pragmatic Approach to Lean Manufacturing!, January 8, 2004

By A Customer

This review is from: Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer (Hardcover)

This is the first book that I have read on Lean Manufacturing that was not a reflection of the author's ego masquerading behind a plethora of platitudes and hedonism. Mr. Hobbs uses a lexicon of terms and applications anybody can understand, making this not only a useful implementation tool, but also a dynamic resource and training tool. As proof, we assembled an implementation team of personnel from all areas of our factory, and were successful in converting two of our product lines in less than twelve weeks simply by following Mr. Hobbs' book. We plan on completing the other seven by the end of Q2. If you want to reap the rewards and benefits as a Lean Manufacturer, I highly recommend this book!