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Table of Contents
Intro
Foreword
Introduction
Contents
About the Authors
Abbreviations
1 The 7 Types of Waste
1.1 Why Do We Distinguish Waste?
1.2 Waste 1: Overproduction
Too Much and Too Soon
It Is Still Waste
1.3 Waste 2: Stock
Stock Gives a Sense of Security
The Money Is Not Only Fixed in the Goods!
Big Trucks and Changeable Weather
1.4 Waste 3: Transport
Parts Tourism
Whether a Few Meters or Halfway Around the World, Both Are Transport
1.5 Waste 4: Motion
Even Short Distances Lead to Espresso
Many Few Also Make a Lot
1.6 Waste 5: Waiting
If It Takes a Little Longer ...
1.7 Waste 6: Unnecessary Processes
Newsletter and Lost Glasses
1.8 Waste 7: Scrap and Rework
Does Not Always Succeed the First Time
1.9 See and Understand Waste
Yes, But ...
... Sometimes You Have to Look Closely ...
1.10 Now It Is Your Turn
2 The 9 Principles for Eliminating Waste
2.1 With 9 Principles to Ideal Production
Why These 9 Principles in Particular?
2.2 Principle 1: Pull Principle
Bake, When the Customer Buys
2.3 Principle 2: Flow Principle
Your Name in Your Color
2.4 Principle 3: Takt Principle
Burger & Co
Distribute Content Equally
2.5 Principle 4: 0-Defect Principle
Break the Defect Chain
A Sustainable Error Culture
0-Defect Is Also a Question of Technology
The Four Stages of Intervention
0-Defect Culture
2.6 Principle 5: Separation of Waste and Value Creation
In the Operating Room, the "Surgeon-Nurse" Principle Applies
2.7 Principle 6: FIFO Principle
First Come, First Served
2.8 Principle 7: Minimum Distance
Many Roads Lead to Waste
2.9 Principle 8: Value Stream Orientation
Everything Has Its Value
2.10 Principle 9: Standardization
The Lean Anchor
2.11 Now It Is Your Turn
3 Lean Methods to See the Waste
3.1 Caution: Methods!
3.2 Welcome to LeanClean Inc.
LeanClean Inc. Needs You
The Three Products of LeanClean Inc.
A Factory Tour
The Competition Does Not Sleep
The Innards of the Elephant
3.3 First Analyze, Then Act
3.4 Method 1: Process Map
The Process Map of the Elephant Product Line
Discussion About Waste, Based on the Process Map
Interesting Facts About the Process Map
3.5 Method 2: Value Stream Analysis
The Value Stream of the Handle of the Elephant
The Customer and the Supplier
The Flow of Information
The Material Flow
The Timeline
Waste Flashes
And Now It Is Your Turn ...
3.6 Method 3: OEE
A Matter of Time Regarding the Plastmaster 2000
Caution When Comparing OEEs
From Automatic OEE to the Smart Factory
3.7 Method 4: Handling Step Analysis
MuDa In The Engine
What Are Handling Steps?
3.8 Method 5: Operator Balance Chart
Work Distribution in the Elephant Assembly
3.9 Method 6: Spaghetti Diagram
A Long Way to the Mounted Handle
3.10 Method 7: Pareto Chart
From a Gut Feeling to Facts in Two Shifts
Foreword
Introduction
Contents
About the Authors
Abbreviations
1 The 7 Types of Waste
1.1 Why Do We Distinguish Waste?
1.2 Waste 1: Overproduction
Too Much and Too Soon
It Is Still Waste
1.3 Waste 2: Stock
Stock Gives a Sense of Security
The Money Is Not Only Fixed in the Goods!
Big Trucks and Changeable Weather
1.4 Waste 3: Transport
Parts Tourism
Whether a Few Meters or Halfway Around the World, Both Are Transport
1.5 Waste 4: Motion
Even Short Distances Lead to Espresso
Many Few Also Make a Lot
1.6 Waste 5: Waiting
If It Takes a Little Longer ...
1.7 Waste 6: Unnecessary Processes
Newsletter and Lost Glasses
1.8 Waste 7: Scrap and Rework
Does Not Always Succeed the First Time
1.9 See and Understand Waste
Yes, But ...
... Sometimes You Have to Look Closely ...
1.10 Now It Is Your Turn
2 The 9 Principles for Eliminating Waste
2.1 With 9 Principles to Ideal Production
Why These 9 Principles in Particular?
2.2 Principle 1: Pull Principle
Bake, When the Customer Buys
2.3 Principle 2: Flow Principle
Your Name in Your Color
2.4 Principle 3: Takt Principle
Burger & Co
Distribute Content Equally
2.5 Principle 4: 0-Defect Principle
Break the Defect Chain
A Sustainable Error Culture
0-Defect Is Also a Question of Technology
The Four Stages of Intervention
0-Defect Culture
2.6 Principle 5: Separation of Waste and Value Creation
In the Operating Room, the "Surgeon-Nurse" Principle Applies
2.7 Principle 6: FIFO Principle
First Come, First Served
2.8 Principle 7: Minimum Distance
Many Roads Lead to Waste
2.9 Principle 8: Value Stream Orientation
Everything Has Its Value
2.10 Principle 9: Standardization
The Lean Anchor
2.11 Now It Is Your Turn
3 Lean Methods to See the Waste
3.1 Caution: Methods!
3.2 Welcome to LeanClean Inc.
LeanClean Inc. Needs You
The Three Products of LeanClean Inc.
A Factory Tour
The Competition Does Not Sleep
The Innards of the Elephant
3.3 First Analyze, Then Act
3.4 Method 1: Process Map
The Process Map of the Elephant Product Line
Discussion About Waste, Based on the Process Map
Interesting Facts About the Process Map
3.5 Method 2: Value Stream Analysis
The Value Stream of the Handle of the Elephant
The Customer and the Supplier
The Flow of Information
The Material Flow
The Timeline
Waste Flashes
And Now It Is Your Turn ...
3.6 Method 3: OEE
A Matter of Time Regarding the Plastmaster 2000
Caution When Comparing OEEs
From Automatic OEE to the Smart Factory
3.7 Method 4: Handling Step Analysis
MuDa In The Engine
What Are Handling Steps?
3.8 Method 5: Operator Balance Chart
Work Distribution in the Elephant Assembly
3.9 Method 6: Spaghetti Diagram
A Long Way to the Mounted Handle
3.10 Method 7: Pareto Chart
From a Gut Feeling to Facts in Two Shifts