Fundamental Concepts of Lean

As I have been looking over my notes from the last few publications and improving our curriculum for our upcoming Japan trip experience, I came across a new, overlooked concept from our newly published book by Shigeo Shingo, Fundamental Principles of Lean Manufacturing. Shigeo Shingo called it the Coefficient of Layout Efficiency. It is a ten-step model that provides you with all the detail, analysis breakdowns, diagrams, and forms to establish the best layout for your facility.

How many times do we, as managers and employees, question the design and layout of our processes? We discuss it, yes, but we never take it further than choosing one person’s idea over another. Well now we have a methodology to assess layout efficiency and I urge you to address this issue in your own workplace. Just this week I had the opportunity to interview Mr. H from Toyota, who provided some additional insight into my understanding of Kaizen and how Dr. Shingo contributed to Toyota’s success. Generally we all see Kaizen with “tool glasses” on; for example 5S, Suggestion Systems, SMED, TPM, Workshops, Kanban, etc. He explained that this kind of Kaizen activity is called, “Quickening the Factory”. This level of Kaizen falls under the umbrella of the current situation – essentially, making a process more efficient as it is currently designed. This includes the layout of the factory. Mr. H illustrated this by drawing out the TPS Pyramid and explained:

“Dr. Shingo wanted us to consider aspects of improvement above ‘Quick Factory’ concepts. By reaching a higher level of analysis you will be able to make improvements far beyond ‘Quick Factory’ solutions. Dr. Shingo wanted us to address C-Level improvements not F-Level improvements.”

The reason this book, Fundamental Principles of Lean Manufacturing, is such a valuable resource is that it not only provides you with time tested, proven ideas and concepts, but Dr. Shingo also guides you through the processes of problem solving and adapting these techniques to the uniqueness of your own workplace. The greatest value Dr. Shingo provides is showing us how to achieve higher level improvements. As I said when I first read this book, “I could spend an entire career training and teaching people about this overlooked and undervalued system that Dr. Shingo articulated to us”. He provides the detailed models that allow you to more easily achieve your goals, therefore I encourage you to add this to your library. Even if you purchase this book with the sole intention of gaining insight into the Coefficient of Layout Efficiency, the book has more than paid for itself in the knowledge and perspective that you will gain.

I feel very fortunate to be able to discover such knowledge and insights, and be able to share these with you. As a leader of any kind you need to understand the details of effective management so that you can empower your people to discover and utilize tools like this, in order to leverage their creativity and talent. Dr. Shingo has done it again – we only need to become better students of his work. Our Japan trip provides the environment to re-discover these great methods, teaches you how to use them in your own unique business, and also provides you with access to the experts who use these methods and techniques in their daily lives. I look forward to discovering new insights with you and providing you with new knowledge.

Collin McLoughlin

President

Enna