| | |  | Standardization/Standard Work | Home » » » Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process | | | | | | | Description: | | Originally developed at Toyota, the approach to manufacturing known as Kanban has helped revolutionize how corporations and suppliers achieve maximum efficiency in getting products to and from the assembly line. When implemented properly, the Kanban technique minimizes waste, avoids overproduction, and ensures quick response to changes and problems. Kanban Made Simple is the first simple 'how-to' guide for incorporating the just-in-time ingenuity of the Kanban system into any manufacturing environment. From the Japanese word for "visual record," the technique dictates that suppliers deliver parts to the warehouse only as they are needed, reducing storage in the production area. Using before-and-after case studies, this easy-to-follow guide contains information on establishing project goals, forming a Kanban team, and designing the process. Kanban Made Simple helps readers decide if Kanban is right for their organization, then teaches them how to train personnel and administer the program. A ready-to-use CD-ROM, included with the book, guides the Kanban team through the entire implementation process. | | | Product Details: | | | Author:
| John M. Gross | | Hardcover:
| 256 pages | | Publisher:
| AMACOM | | Publication Date:
| May 13, 2003 | | Language:
| English | | ISBN:
| 0814407633 | | Package Length:
| 9.1 inches | | Package Width:
| 6.0 inches | | Package Height:
| 1.1 inches | | Package Weight:
| 1.15 pounds | | Average Customer Rating:
|  based on 6 reviews |
| | | | Customer Reviews: | |
Average Customer Review:
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 Something is missing...Mar 27, 2008
I expected that book to be step-by-step instruction. Generally it is, but some things are missing: how to calculate order points, alert (red level); THERE IS NOTHING ABOUT HEIJUNKA - production leveling - there are only 3-4 sentences which tell you that it might be a problem if your Customer order more than +/ 20% - it's not enough! KANBAN will kill any company without heijunka (sometimes very slow but painfully/costly).
CD - waste of time (as it was already written).
3 of 3 found the following review helpful:
Good book - mainly about data collection and kanban sizingApr 10, 2007
A few years ago I was looking for a book about how to size a kanban system. This book is exactly about this topic and follows a step by step approach. Many people believe, that implementing a Pull-system is possible by following cooking-receipts, it is not. Anyone thinking about implementation of a Pull-system, should first understand when it makes sense and when there are better alternatives for your business. Pull-systems can be used as long as your product variaty is not to broad and when demand varies within +/- 20%.
The book starts with what data has to be collected and even gives some hints about consistent data (even wrong data examples are given). What I missed a little bit, are more information about the real meaning of the replenishment interval and sometimes the numbers calculated in the example seem to be rounded in a fancy manner.
Furthermore when sizing the kanbans it would be usefull to have a better description (example/ sketch) what the replenishment quantity and buffer quantity means. Without this information the reader beeing new in this area has to make a guess on his own. The different visual signs and cards (+equivalents) to control your kanban system are well explained.
What is missing in this book? The book is weak when it comes to other very important issues as line lay-out, the importance of cell implementation, load leveling (heijunka), line-balancing (vs. takt-time) etc. The book "Pull Production for the Shopfloor" from the Productivity Press Development Team is very easy to read and provides many information and simple drawings about the missing knowledge. Furthermore the book presents calculations about the influence of reducing lot size (set-up time), reducing unplanned machine downtime and the influence of scrap/rework. If you are really interested in understanding the bad influence of large lot size, machine unavailability and scrap/rework you need to take a deeper look into Operations Management, as provided by Quick-Response-Manufacturing, Factory Physics or other usefull books..
This book will do an excellent job combined with other books that cover the missing points. Adopting this production system requires more than sizing a system, you need to change the mindset of your workforce for relentless persuit of continuous improvement (Kaizen) and some understanding about the tools used together with this system: 5S, TPM, SMED, ZQC etc. Furthermore for complex manufacturing systems the question where to start with Pull-implementation of a single line becomes crucial. Sometimes you do not need even to turn your whole processes to pull and a mix of push-pull lines and pull lines might be a better approach for your needs. For people interested in making a splash and where Pull-systems do not seem to be the right approach, I strongly recommend to read Quick-Response-Manufacturing. This approach has many insights in common with JIT/Lean but is much easier to apply. The knowledge from operations management itself will even help to understand pull-systems and what they are based uppon.
Enjoy reading,
Oliver
1 of 1 found the following review helpful:
GoodMar 16, 2007
It covers all the important points of a Kanban System, yet you can read it in no time. I like it.
4 of 4 found the following review helpful:
 Great Implementation BookJan 16, 2005
Kanban Made Simple is a great book to help in teaching people how to implement Kanbans. While many people conceptually understand Kanban, they do not understand all the elements that go into sizing the kanban and into the design of the kanban. This book addresses all these elements (sizing, type, visual management, rollout, and batch size reduction)in a step by step method. I recommend it to all my clients.
0 of 1 found the following review helpful:
Good BUTJan 14, 2005
Book is well organized. Chapters 3 (Data Collection) and 4 (Sizing the Kanban)need more detail. Overall, the book does take you through the process. CD is a waste of time. All the files are in PDF format. If these were in Word or Excel, it would be much easier to use.
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