Lean implementation : applications and hidden costs


PrefaceLean ThinkingIntroductionAttributes of a Lean OrganizationKnow Your CustomerRespect for PeopleManagement Make Decisions Focusing on the Long-Term Value as Opposed to the NowCreate a Culture That Will Allow Workers to Feel Empowered and Free to Bring Problems to Management's Attention As Soon As They AriseA Continual Focus on Continuous ImprovementMaintain a Focus on Quality ContinuouslyAvoid Overproduction (Use a Pull System)Develop Leaders Who Are Inquisitive, Leaders Who Walk the Talk on a Daily Basis, and Are Worker FriendlyDevelop a Process That Can Monitor Performance As Well As Locate Improvement AreasDevelop a Culture That Embraces a Learning Organization PhilosophyWhy Go Lean?Delivering Customer ValueDefining the Waste StreamActions That Create FlowProduce What Is Used by the Customer and Avoid OverproductionSeek Perfection to Achieve Continuous ImprovementOverview of Lean ToolsValue Stream MappingSix Sigma and LeanStaying LeanSummaryLean Thinking Leadership TeamIntroductionLeadership Responsibilities in OrganizationsVision TenetPeople TenetStrategy TenetDecision TenetFollowership and Leadership RolesQualities of a Good LeaderA Good Leader Is ConfidentA Good Leader Acts with PurposeA Good Leader Demonstrates Exemplary CharacterA Good Leader Is EnthusiasticA Good Leader Is FocusedA Good Leader Is Able to Build and Retain Good RelationshipsA Good Leader Is Committed to Continuous Improvement and ExcellenceLean Thinking BehaviorsWalking the TalkLeadership StylesThe Influential LeaderThe Accountable LeaderThe Lean Thinking Leadership TeamSummaryLean CultureIntroductionWhat Is a Lean Culture?PracticesBehaviorValuesSymbols and LanguagesAssumptions and PerceptionsLean ThinkingSubculturesEstablishing a Culture of ChangeChange ManagementSupervisor's Role in Change ManagementAssessing CultureDocument ReviewConducting the SurveyFocus Group and Individual InterviewsShaping CultureCommunication between Workers and ManagementFostering Trust from WithinConsistency in Actions and ReactionsHuman Resource Policies and PracticesManagement Time in the Work AreaDelegate Lower Level DecisionsEmployee InvolvementLeadership Charting the WayEmployee Engagement in a Lean CultureIntroductionDefining Employee EngagementEmotional Connection in the WorkplaceEmployee Engagement Impacts and BenefitsImproved MoraleEmployee Engagement and Increased ProductivityTeam CohesionInnovation and Engaged EmployeesHigher Level of Trust Contributes to EngagementThe Actions of an Engaged LeaderCommunication StrategyHuman Resource Policies and PracticesEvaluating Employee EngagementEmployee Engagement SurveysFocus Group Discussions: Employee EngagementSummarySuccession Planning Strategy in a Lean EnvironmentIntroductionWhat Is Succession Planning?Developing a Succession Planning StrategyWhat Does a Good Succession Strategy Look Like?Identify Key PositionsIdentify Positions That Are Hard to FillIdentify Key CompetenciesIdentify CandidatesInternal Candidate CommunicationConduct Skill Gap AnalysisDefine and Implement Training PlanPromoting from WithinKnowledge Gathering and RetentionContinuing EducationSuccession Planning in a Lean EnvironmentSummaryReferenceTalent Management and Retention and the Hidden CostsIntroductionWhat Is Talent Management?Balancing Employee Needs with Organizational DemandsThe Value of a Flexible WorkforceKnowledge Retention and TransferEmployee Retention StrategyEmployee RecognitionTalent CareWhy Do Employees Leave Their Companies?Relationship with the SupervisorIncompetent LeadershipLack of Challenging and Meaningful WorkLack of Career Growth and Advancement OpportunitiesComparable Pay Does MatterWhy Do Employees Stay with Their Organization?The Impact of Meaningful and Satisfying WorkTrust in the Leadership Team and Its ImpactCareer Growth in a Learning EnvironmentFair Pay and BenefitsFeeling of ValueSupportive ManagementSummaryEmployee Development and the Hidden CostIntroductionWhy Train?The Role of the Leadership TeamTraining Needs AnalysisTraining Delivery MethodsClassroom TrainingOn-the-Job TrainingMentoringJob RotationCoachingShadowingTraining Constraints in Lean EnvironmentsContinuing EducationKnowledge ManagementLearning CultureAssessing the Effectiveness and Quality of a Training ProgramSummaryEnvironment Health and Safety in a Lean EnvironmentIntroductionComponents of Corporate Environment Health and Safety ProgramEnvironmental ProtectionWorker Safety and HealthEnvironmental Health and Safety TrainingHealth and Medical ServicesRadiation Safety ProgramEliminating Waste through ComplianceThe Role of an Effective Environment Health and Safety ProgramEnvironment Health and Safety Programs Value PropositionThe Reality of Workforce PerceptionThe Real Cost of AccidentsApplying Lean Principles and Application to an EH&S ProgramThe Synergy between Lean and Health and Safety ProgramsLean Tools UsageSummaryImplementation Pitfalls and Hidden CostsIntroductionWhat Are Pitfalls and Hidden Costs?A Project Management Approach to LeanOrganizational AlignmentWhy Lean Fails?Performance MetricsRetention of Staff in a Lean EnvironmentMinimizing Risk through LeanThe Impact of Trust on Costs and the Pitfalls of Lean ImplementationThe Impact of CultureThe Role of SubculturesLean ProcurementHidden Costs Are MultifacetedCapturing the Actual Cost of LeanSummaryLean Implementation Case StudyIntroductionThe Project DescriptionIdentification and Quantification of the ProblemBrainstormingProcess MappingWorker InterviewsJob Hazard AnalysisWork ObservationBenchmarking and Technology SelectionConducting the PilotImplementation of Technology to Reduce Risk in Conducting Chemical Inventories: A Case StudyLean Thinking LeadershipStrategic Thinking LeadershipPeople Oriented and Relationship BuilderPulse of the CustomerSeeking Perfection AlwaysEmployee Engagement and TrainingRegulatory ImpactEnvironment, Health, and Safety AspectsThe People Aspects of ImplementationCase Study Implementation Pitfalls and Hidden CostsSummaryEvaluation Resource PacketOrganization Trust QuestionnaireOrganization Culture QuestionnaireEmployee Engagement QuestionnaireLean QuestionnaireOrganization Learning Self-AssessmentTraining Feedback FormAttributes of a Good Assessment
 
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