Consultants in Lean Manufacturing Á Manufacturing Strategy

"10 Steps to Effective Kanban" Honorable Mention for "Best Paper"


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Strategos Book Reviews

Quarterman Lee's Favorites 

Some of these books are outside the usual Lean Manufacturing literature. They often give unique insight or contribute to fundamental theory. Some delve into the history and personalities and thus help us understand the present situation or conventional wisdom.

Quarterman Lee PhotoAll are works that I have read, sometimes over and over.  I hope you find them as valuable and interesting as I have.

Quarterman Lee

Plant Layout
& Facility
Planning
Lean Book Reviews--Warehouse Modernization

Warehouse Modernization and Layout Planning

NAVSUP Pub 529

Sims Consulting Group

Warehouse Modernization and Layout Planning Guide NAVSUP Publication 529

Sims Consulting Group

Lean Book Reviews--Warehouse ModernizationThis massive sourcebook for warehouse design is packed with over 700 pages of illustrations, procedures and design data. It explains how to analyze, select, design and evaluate warehouse operations, plans and equipment. It contains detailed procedure for analysis of inventory and transaction activity and how to use this analysis for equipment selection.

NAVSUP 529 was prepared by The Sims Consulting Group, a Strategos- International affiliate. It has become the de facto standard for all DoD warehouses. The cost and other data is surprisingly accurate even though several years old.

Lean Book Reviews--Handbook of Facilities

Handbook of Commercial & Industrial Facilities

Q. Lee & W. Wrennall

Handbook of Commercial and Industrial Facilities Management

Quarterman Lee & William Wrennall

Lean Book Reviews--Handbook of FacilitiesA company's facilities are often its largest single investment and a key to the effectiveness of its operations.

This book is a complete reference for those who design and manage factory buildings, office complexes, hospitals, and other commercial and industrial facilities. Engineers, architects, and building managers will use it for information on various aspects of designing, evaluating, and selecting facilities plans. They will learn about the latest strategies for managing different types of projects, and get solutions to a wide range of problems, such as leasing, contracts, regulatory matters, construction, and maintenance.

Lean Book Reviews--Manufacturing Plant Layout

Manufacturing Plant Layout

Edward J. Phillips

Manufacturing Plant Layout: Fundamentals & Fine Points of Optimum Facility Design

Edward J. Phillips

Lean Book Reviews--Manufacturing Plant LayoutA step-by-step guide to planning new factories and plant rearrangements by Strategos-International affiliate Ed Phillips. This book has analytical methods for space, activity-pair relationships, materials handling, and alternative layouts. It weaves together layout, cells, JIT, demand-flow and TOC in addition to traditional job shop and line operations.

Accounting
&
Metrics
Lean Book Reviews--Relevance Lost

Relevance Lost-- A History of Management Accounting

 Robert Johnson/Robert Kaplan

Relevance Lost-- a History of Management Accounting

H. Robert Johnson & Robert S. Kaplan

 

Lean Book Reviews--Relevance LostDescribes the evolution of accounting in American business, from the early textile mills to present-day computer-automated manufacturers. "Understanding the reasons behind the obsolescence of existing systems should provide improved rationale for organizational change." Johnson and Kaplan argue that outdated accounting undermines American manufacturers' competitiveness. Many accounting systems report highly inaccurate product costs and provide misleading targets for productivity and efficiency efforts.

Lean Book Reviews--Balanced Scorecard

The Balanced Scorecard

Robert Kaplan/David Norton

The Balanced Scorecard

Robert S. Kaplan & David P. Norton

 

Balanced ScorecardRunning a business for the long term requires more than financial metrics. The Balanced Scorecard shows how to link metrics and strategy. It provides a system for investing in customers, employees, new product development, and in systems-rather than pumping up short-term earnings.

Lean Book Reviews--Performance Measurement

Performance Measurement For World Class Manufacturing

Brian H. Maskell

Performance Measurement For World Class Manufacturing

Brian H. Maskell

Lean Book Reviews--Performance MeasurementMetrics and measurements are important both as gauges to measure progress and as motivators. People respond to the way they are measured. This book has a good balance of theory and practice with many charts and examples. Chapter 9 on measuring social issues is especially good. -QL

Manufacturing Strategy
Lean Book Reviews--Competing Against Time

Competing Against Time

George Stalk & Thomas M. Hoyt

Competing Against Time

George Stalk & Thomas M. Hoyt

Lean Book Reviews--Competing Against TimeThis is the FedEx Bible. Absolutely, positively the best piece of work that relates system dynamics to business success. 

  • Stalk and Hout argue that time is the underlying factor of competitive success.
  • Faster product development brings more new products to market ahead of competitors.
  • Faster fulfillment is a direct competitive advantage in most markets.
  • Faster production increases efficiency and effectiveness.
  • Faster administrative processes reduce overhead and costs. Saving time throughout the business increases system stability. -QL
Lean Book Reviews--Restoring Our Competititve Edge

Restoring Our Competitive Edge

Robert Hayes & Stephen C. Wheelwright

Restoring Our Competitive Edge

Robert Hayes & Stephen C. Wheelwright

Restoring Our Competitive EdgeTopics include: Manufacturing Strategy, Experience Curves, Manufacturing Focus, and Capacity Strategy.

While this book is a bit dated (1980) it is still an excellent source for Manufacturing Strategy. It is especially good for large multi-site companies. It includes an interesting chapter on German and Japanese approaches to manufacturing. -QL

Lean Book Reviews--Manufacturing Strategy

Manufacturing Strategy

Terry Hill

Manufacturing Strategy

Terry Hill

Manufacturing StrategyOne of the three or four best books on Manufacturing Strategy. How to develop your Manufacturing Strategy  from fundamentals rather than formulae. Hill discovered the mechanism that links manufacturing and marketing strategy: Order-winning criteria. Includes fascinating case studies that bring the subject to life. -QL

Manufacturing: the Formidable Competitive Weapon

Wickham Skinner

Manufacturing: The formidable Competitive Weapon

Wickham Skinner

Manufacturing Strategy Wickham Skinner relates some history of manufacturing from the Manufacturing Strategy perspective and outlines the way forward. In this important book the author discusses focused factories and provides the broad outlines that eventually become the discipline of Manufacturing Strategy. A must-read for top manufacturing managers.

The Human Side
Power & Influence

Power & Influence

John P. Kotter

Power & Influence

John P. Kotter

Power & InfluenceExcellent book on how individuals can function effectively in today's fluid, informal organizations. Well written and very readable.--QL

 
Influence Without Authority

Influence Without Authority

Allan R. Cohen & David L. Bradford

Influence Without Authority

Allan R. Cohen & David L. Bradford

Influence Without AuthorityThis is an individual's guide to effectiveness in modern organizations which require cooperation across lines of authority. Most of us have known people at mid-levels in organizations who have influence that goes far beyond their official position. Cohen and Bradford explain how to build relationships and have a positive effect in your organization.--QL

Decoding The DNA of Toyota Decoding The DNA of The Toyota Production System

Steven Spear & H. Kent Bowen

Decoding The DNA of The Toyota Production System

Steven Spear & H. Kent Bowen

Decoding The DNA of Toyota How does Toyota stay on top year after year and decade after decade? This Harvard Business Review reprint compares corporate culture to the DNA of living organisms. The emphasis is on Toyota Motor Company. -QL

Lean Book Reviews--Kaizen The Art of Creative Thinking

Kaizen & The Art of Creative Thinking

Shigeo Shingo

Kaizen & The Art of Creative Thinking

Shigeo Shingo

Lean Book Reviews--Kaizen The Art of Creative Thinking Problem solving--It seems pretty basic. After all, that is what engineers and managers are supposed to do. Yet, most of us are pretty poor at it as individuals and even worse in group settings. Our thinking is haphazard, we rarely use the available tools and our minds return to minor variations of the familiar. In this book, Shingo explores thinking, problem solving and creativity at a fundamental level. He has the Japanese gift for obsessing on a simple concept until it is understood completely. This contrasts with the usual Western approach of snatching a simple concept and complexifying it beyond all comprehension. The translation and editing is superb.

General Lean Manufacturing
Lean Book Reviews--The Goal

The Goal

Eliyahu Goldratt

The Goal

Eliyahu Goldratt

Lean Book Reviews--The GoalWritten as a novel this book will not overshadow Ernest Hemingway's reputation but it is good. Beware of imagining that you know everything

A "must read" for any manufacturing manager. Goldratt takes some sound concepts from queuing theory and presents them in unique ways.

important after reading it.

The Theory of Constraints is not manufacturing strategy but is sound, necessary, underlying knowledge. --QL

Lean Book Reviews--Lean Thinking

Lean Thinking

James womack & Daniel Jones

Lean Thinking

James womack & Daniel Jones

Lean Book Reviews--Lean ThinkingExcellent management-level introduction to Lean Manufacturing and Lean operations. The explanations are simple, sensible and straightforward. It includes case histories from a variety of firms in the US, Germany and Japan.  -QL

 

Lean Book Reviews--Zero InventoriesZero Inventories

Robert W. Hall

Zero Inventories

Robert W. Hall

Lean Book Reviews--Zero InventoriesThe most readable and complete documentation of Toyota and Japanese manufacturing from the 1980's.

Excellent chapters on setup reduction, Kanban, MRP and production control. Also includes early examples from US manufacturers. -QL

Lean Manufacturing History
Ford The Men & The Machines

Ford the Men & The Machines

Robert Lacey

Ford the Men & The Machines

Robert Lacey

Ford The Men & The Machines Excellent history of the Ford Motor Company and the Ford family through 1985. This book gives perspective to Bill Ford's current struggle to once again transform the company.

Includes Ford's early failures, triumph of the Model T, Edsel's struggle with his father, Sorensen's success at Willow Run and Henry Ford II's rebuilding after WWII.  -QL

Lean Book Reviews--My Life & Work

My Life & Work

Today & Tomorrow

Henry Ford with Samuel Crowther

My Life & Work

Today & Tomorrow

Henry Ford with Samuel Crowther

Lean Book Reviews--My Life & WorkMany consider Henry Ford the originator of Lean Manufacturing. In these two wide-ranging books, Ford discusses manufacturing, business, and other philosophy.

The books are surprisingly well-written thanks to Ford's ghost writer, Samuel Crowther. The manufacturing parts are profound and prophetic. Take the other parts of Mr. Ford's philosophy with a grain of salt.  -QL

Lean Book Reviews--The People's Tycoon

The People's Tycoon

Steven Watts

The People's Tycoon

Steven Watts

Lean Book Reviews--The People's TycoonA former boss of mine from the mid-1960's had known Henry Ford quite well. He said "The old man wasn't crazy, he just had a damn lousy personality." 

Steven Watts explores, in this book, the many sides of Henry Ford that most of the other works have missed about this complex and eccentric man, his personality, motivations and early life.

There is little in this book about manufacturing or Ford's ideas on manufacturing. It is, however, a great read for those who are mystified by some of his stranger behaviors. -QL

Lean Book Reviews--Willow Run

Willow Run: Colossus of American Industry

Warren B. Kidder

Willow Run: Colossus of American Industry

Warren B. Kidder

Lean Book Reviews--Willow RunBy late 1944 the Willow Run Bomber Plant was producing more than 20 B-24 aircraft per day.  Read about the remarkable industrial achievement of Charles E. Sorensen and the people of Ford Motor Company. Pictures, drawings and plant layout. Just In Time Production on a fantastic scale! --QL

Systems Thinking & Manufacturing Science
Lean Book Reviews--The Fifth Discipline

The Fifth Discipline Fieldbook

Peter Senge

The Fifth Discipline Fieldbook

Peter Senge

Lean Book Reviews--The Fifth DisciplineSenge presents Systems Thinking and Learning Organizations in a practical format. This book is filled with examples, exercises and discussion on how to use The Fifth Discipline. Highly recommended -QL

Business Dynamics

Business Dynamics

John D. Sterman

 

Business dynamics

John D. Sterman

Business DynamicsHow are innovative products like plagues? Why do new highways fail to ease traffic congestion? Why is linear growth an illusion? The answers to these and many other questions are in this remarkable book.

Though intimidating at first, if only because of its size, Sterman's book is readable and does not require higher math. He explains the behavior of complex business and other Socio-Technical systems clearly, explicitly and briefly.--QL

Factory PhysicsFactory Physics

Wallace Hopp & Mark Spearman

Factory Physics

Wallace Hopp & Mark Spearman

Factory PhysicsThe Japanese inventors of Lean Manufacturing were pragmatists. They did not seem to understand, or at least, could not explain why the system worked from a fundamental level. Hopp and Spear offer those explanations.

From the fundamental laws and sciences of physics, systems and queuing theory, they take a quantitative and rigorous approach to factory systems. This book offers many insights. It can be read at a descriptive level or the reader can delve into the detailed math. --QL

ChaosChaos- Making A New Science

James Gleick

Chaos- Making A New Science

James Gleick

ChaosProbably the best layman's introduction to the science of Chaos. Topics include dynamical systems and fractals. Includes history and personalities prominent in the field, fascinating images. Manufacturing systems are highly subject to chaotic effects and knowledge of their behavior is important to manufacturing managers and strategists. -QL

Logistics, Suppliers & Supply Chain
Lean Book Reviews--Lean Logistics

Lean Logistics

Michel Baudin

Lean Logistics

Michel Baudin

Lean Book Reviews--Lean Logistics Michel Baudin has written a very complete but very readable book on Lean Logistics and suppliers.

 Perhaps the most important part of this book is Part V where he discusses business relationships, an oft neglected part of the Lean Supplier equation. There is far more to the business of Lean Logistics than many have imagined. 

Improving The Extended Value Stream

Improving the Extended Value Stream

Darren Dolcemascolo

Improving the Extended Value Stream

Darren Dolcemascolo

Improving The Extended Value StreamDarren Dolcemascolo presents a step-by-step plan for extending lean manufacturing across the entire supply chain. He makes the case for improving the extended value stream by demonstrating the benefits: increased profitability, reduced lead times and inventory, and better quality. Well written and complete.

Cells & Workstation Design
Handbook of Cellular Systems

Handbook of Cellular Manufacturing Systems

Sharukh Irani

Handbook of Cellular Manufacturing Systems

Sharukh Irani

Handbook of Cellular SystemsThis is an edited book with many authors. I contributed several chapters. It covers the entire range of Cellular Manufacturing and offers different viewpoints.

The book is well balanced between theory and practice. some chapters are academic and others practical; a complete source on Cellular Manufacturing. --QL

Lean Assembly

Lean Assembly

Michel Baudin

Lean Assembly

Michel Baudin

Lean AssemblyExcellent management-level introduction to Lean Manufacturing and Lean operations. The explanations are simple, sensible and straightforward. It includes case histories from a variety of firms in the US, Germany and Japan.  -QL

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