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What if I told you Operational Excellence is not about learning and applying, but unlearning and abandoning? One-size-fits-all strategies, management, and production systems try to impose their behavioral codes. The results could only be perfect if employees were machines that worked according to preloaded software. However, people act by their feelings. They feel depending on how they think and think according to their desires and beliefs. Systems often ignore humans and try to drive their behavior. But to realize the true potential, we must understand the human condition and utilize the non-productive energy that cannot be visualized and eliminated by systems like Lean and 6-Sigma. If systems cannot measure the problems they create, they cannot reach excellence. Developing a Toyota like culture takes decades. Still, there is a way. You don't need to learn anything new for Operational Excellence. It is all about avoiding mistakes. Most managers have similar goals, make similar mistakes, fail, and learn the same things. With the unique combination of Western Philosophy, psychology, and neuroscience, this book decodes the secrets of Operational Excellence based on the experience of a former Toyota General Manager who learned TPS in Japan and successfully implemented it in multiple automotive OEMs. Instead of telling what to do to achieve probable success, I decrypt what not to do to avoid guaranteed failures. If the only source of knowledge is experience as Einstein put it, this book can save you many years of trial and error and common failures. Reviews "5S was once 4S, we added sustain to cope with cultural differences surrounding discipline. The 8 wastes were once the 7 wastes, we added the 8th to cope with cultural differences surrounding respect for humanity. These are both excellent examples of how we often detract from wisdom by adding to it. Thinking we can improve things we don't yet understand has led people down the wrong path for time immemorial. Early in this book, Levent Turk grabs this error in thinking and nails it to the wall with this line; Human potential is not something we need to unleash, but rather, something we frequently block... the rest of the book just gets better from that point forward. The author's firsthand training in Toyota, Japan, senior leadership positions in Toyota over 15 years, and 12 years' experience implementing TPS into non-Toyota production environments provides this book with solid foundations. If this were the book we'd inherited in the 90s, maybe we would now be surrounded by leaders who realise a high-performance culture is more to do with their own beliefs in what good looks like and the conditions they create for human brains to survive in ... and not about training tools and tracking KPIs. What others take a whole book to say, Levent Turk captures in a single paragraph or sentence. This is a book of a 1000 books. If you are in a leadership position and want to create a high-performance culture, do yourself a favour. Hang onto every word, ponder every page, digest, understand, reflect. You will not find a better way to spend your time." David Bovis "Levent Turk has written a remarkable book, one that is truly unique in the genre of TPS and Lean. More than a reflection of a lifetime in business, it is a synthesis of ideas woven into a rich tapestry of valuable insights that readers will enjoy reflecting on and putting into action." Professor Bob Emiliani
"I'm a huge fan of High Output Management and Setting the Table [...] Luca's Best Practices for Operational Excellence took my management to the next level. It's been almost a month since I started implementing the principles, but I can already say that I've noticed a significant improvement in my company's morale [...] That feels amazing." – Molson Hart, Viahart CEO Inside, you’ll find the solutions to your problems as a manager: How to manage “difficult” employees? How to get your subordinates to solve their own problems? How to get more time for yourself to work on what’s important? How to introduce a culture of mutual trust, respect, and accountability, in a team which is demotivated or full of personal problems. What’s inside The 4 Principles of Operational Excellence that determine whether your organization will operate smoothly or always react to the last problem, whether your subordinates respect you and each other or operate with defensiveness and distrust. The 8 Best Practices of Operational Excellence that effective managers use weekly and monthly to ensure that the Principles are followed in practice every day, even when conditions are not optimal, even when they are not around. How to get buy-in, a roadmap for an impactful roll-out, and systems to sustain the change. This book does not let you alone with the complex reality of implementing change in a big company where multiple projects and agendas are involved. This book will help you improve the way your team works, leading to the following benefits: Less stress: as your team’s Operational Culture improves, they will learn how to solve alone problems you would have to micromanage instead. More time: as your team takes care of its own problems, you will be freed from running after emergencies and work on the things that matter. More respect: as you become a better leader, and your subordinates become better teammates, valuing each other’s work, you will become more respected and valued. More budget: as your team improves its output, your team’s bottom line contribution becomes available to be redistributed as budget and bonuses for you and your team. A better career: the skills you will learn with this book are rare and thus valuable. They will make you a more valued and respect employee, leading to a successful career. A complete playbook with best practices you can apply starting today in your company, to translate into impactful action the Principles of Operational Excellence. It includes comparisons between the actions of good managers and bad ones, lots of detailed examples, and word-by-word scripts. Other books only describe how an effective company looks like, ignoring how to get there. This book doesn’t leave you alone with the implementation. It proposes practical tactics and word-by-word scripts you can use to obtain buy-in from the Top Management and roll-out the change initiatives. THE COMPLETE TOOLKIT FOR THE OPERATIONS MANAGERS & SUPERVISORS IN MANUFACTURING & LOGISTICS Handle unmotivated workers and instill newfound proactivity. Get your workers to work safely, even when the boss is not looking. Get your employees to keep an orderly work-floor, even when they are not motivated. Get your quality up while decreasing the cognitive load of your workers. Manage a fast-changing company, where workers fail to keep up with growth and change. In this handbook, you will find all the procedures you need to run your operations smoothly.
"A useful guide for scholars, practitioners and those involved in engineering, management, and business fields"--
Detailing the role of senior management in achieving a successful transformation to organizational excellence, Simple Excellence: Organizing and Aligning the Management Team in a Lean Transformation charts a course of simplification through the complexity often associated with managing performance improvement initiatives. It spells out the roles of key individuals on the management team—including those from sales and marketing, human resources, purchasing/supply chain, information technology, finance, and engineering. Maintaining a focus on the big picture, this book explains what value streams are and how to use them to structure your business so that all stakeholders are aligned with what matters most. It reduces constraint management to its most practical terms and lays out a sound approach to accounting that enables everyone to spend money where it adds value and stop spending where it doesn’t. Drive your management team with dedicated allegience to the concept of value enhancement Propel your organization to higher performance through the employment of Lean culture and decision-making principles Enact management structures needed to put new ways of thinking into play Focus on the bottom line with the right performance metrics Written by respected authorities with extensive experience helping leading organizations achieve Lean transformation, the text includes case studies from high-profile organizations recognized for operational excellence. Addressing human resources management practices, it explains how to manage the day-to-day operations and pricing factory capabilities for the greatest possible profits. It also discusses the ongoing process of strategic planning to help you move away from annual goal setting, toward a dynamic process of engaging the entire company in the effort to provide your customers with an improved sense of value.
Provides the foundation and tools that are essential for an enterprise to bring Operational Excellence into their organizational culture; gain maximum results, benefits and value Strategies for and implementing details for enterprises at all levels of maturity from those with programs in place to those looking to improve safety, health, environment performance as well as the efficiency and effectiveness of their operations Includes topics from concept to sustainability satisfying knowledge requirements of all levels in the organization Defines program objectives; develops improvement strategies; identifies and prioritizes improvement opportunities; implements improvement plans; monitors, continuously improves and sustains results Applicable to a broad variety of operating enterprises, academic institutions and third party implementing organizations
In the corridors of corporate history, the Toyota Way is more than just a chapter; it's a testament to the art and science of exceptional management. It's a philosophy rooted in the pursuit of perfection, an unyielding commitment to efficiency, quality, and innovation. But it's not merely a set of principles etched in stone; it's a living, breathing philosophy that has adapted to changing times while holding steadfast to its core values. As we embark on this journey, prepare to uncover the secrets behind Toyota's unmatched success, the principles that have catapulted it to the zenith of operational excellence. From the relentless pursuit of continuous improvement to a profound respect for people, from a visionary long-term outlook to the relentless quest for value stream perfection, these principles are not just the building blocks of a successful automotive company. They are the cornerstones of a management philosophy that has reverberated far beyond Toyota's factories, influencing industries as diverse as healthcare, aerospace, and manufacturing. We will trace the genesis of the Toyota Way back to its roots, unveiling the cultural and historical contexts that shaped it. We will explore the profound influence of visionaries like Sakichi Toyoda and Kiichiro Toyoda, who sowed the seeds of this philosophy. We will delve into the principles of Jidoka and Poka-Yoke, introduced by Sakichi Toyoda, which laid the foundation for the Toyota Production System (TPS) – a linchpin of the Toyota Way. But this journey is not merely about the past; it's about the present and the future. We will examine how the Toyota Way continues to evolve and shape contemporary business practices, how it has transcended borders, how it resonates with the ever-essential values of employee engagement, customer-centricity, and quality. As we traverse the chapters of this book, be prepared for revelations that will inspire your approach to management, challenge your notions of excellence, and leave you with profound insights into what it takes to excel in the complex and dynamic world of business. The Toyota Way is not just a philosophy; it's a blueprint for excellence, a roadmap to enduring success. So, let's embark on this odyssey, guided by the principles that have made Toyota an icon of operational brilliance. Welcome to "The Toyota Way." Chapter One Introduction to the Toyota Way Chapter Two The Core Principles of the Toyota Way Chapter Three Continuous Improvement The Kaizen Philosophy Chapter Four Cultivating Respect for People Chapter Five Embracing Long-Term Thinking Chapter Six Streamlining Processes through Value Stream Mapping Chapter Seven Standardization and Simplification for Quality Chapter Eight Excellence in Inventory Management Just-in-Time Production Chapter Nine Building Quality into the Process The Built-in Quality Approach Chapter Ten Fostering Continuous Learning and Development Chapter Eleven Impact and Global Adoption Chapter Twelve Conclusion: The Enduring Legacy of the Toyota Way
Total Quality Management (TQM) is structured around a five part model, with the core of the model being the customer-supplier interface. This book includes case studies which illuminate hands-on application of the theories of TQM within the Pacific Rim region and include: Australia, New Zealand, Fiji, Singapore, Hawaii, Hong Kong and Malaysia.
The Shingo Enterprise Excellence Prize Model (SEEM) has exerted global influence over the ways that exceptional organizations formulate/deploy strategy with its focus on processes, Lean thinking, continuous improvement, innovation, workforce development, and supplier strategies. This book details the SEEM, which lies at the heart of the Shingo Prize. It will link the theoretical underpinnings of the SEEM and their implications for practice. Case studies illustrate important points. Selected tools that support practical implementation of the model are discussed and their use illustrated. This book will deepen understanding of why the model works and how implementation can be accomplished.
Operational excellence, as a quest in the prevailing digital era, is predicated on a systems view of the operating environments in business, industry, government, academia, and other organizational entities. This book uses a systems-based approach to show how operational excellence can be pursued, achieved, and sustained. It offers a systems perspective for operational excellence and discusses the evolution of products from the classical operation era to present day digital operations. It covers the role of global markets on domestic operations, presents operational work design and ergonomics, and combines industrial engineering, advanced research, and practical experience. This book is a useful guide for scholars, practitioners and those involved in engineering, management, and business fields.
The key to success and reaching peak performance is integrating three processes to optimize business through the use of human performance improvement tools, lean thinking, operational excellence, along with a strong organizational culture as the underpinning. These components form the basis of the Peak Performance Model. The tools presented in this book, along with the case studies, demonstrate how the model is applied and integrated into company practices. Companies and organizations want to improve their performance, but many have not integrated the right tools and processes. Through the application of the Peak Performance Model, every company can achieve and sustain Peak Performance.