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Book details

  • Genre:business & economics
  • Sub-genre:Industries / Manufacturing
  • Language:English
  • Pages:88
  • Paperback ISBN:9798350993448

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Create a Continuous Flow of Improvements

Eliminate Workflow Interruptions in Manufacturing and Services

By Stephen Wilkinson

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Overview


After being laid off as a project industrial engineer when P&G acquired Gillette, Steve Wilkinson was told he could never find a job in biotechnology, let alone become the leading character in optimizing their manufacturing workflow. Despite this, Steve successfully optimized workflows by eliminating delays, interruptions, and bottlenecks. This resulted in improved costs, productivity, efficiency, and lead times. Steve's notable achievements include saving 100,000 annual labor hours at one site, eliminating production bottlenecks, and reducing costs. Steve is eager to share his expertise to help others achieve better results. He implements a process called "Observe, Analyze, Improve," which simplifies lean processes by eliminating hundreds of wasteful steps in your manufacturing or service processes. "Create a Continuous Flow of Improvement" will accelerate your improvement journey. Together, let's bring back jobs from overseas!
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Description


Go to the work area in Gemba and observe the details of the process to identify improvement opportunities, such as excessive waiting, motion, transportation, inventory waste, latent safety, and quality risks. Learn how to prioritize your observations and choose which ones are worth pursuing. Lean tools such as standard work, visual management, and 5S can be implemented to invoke successful change. Additionally, discover how to monitor and sustain your improvement. The processes inside will teach you how to keep identifying new opportunities daily. Special features inside will equip you with advanced skills for overcoming resistance to change. You will become a hero at work by learning to set up daily agendas, including SQDIP and countermeasure boards that track and resolve all those daily interruptions to your workflow. "Create a Continuous Flow of Improvements" is a call to action to implement these concepts and develop leadership skills to help advance your improvement journey.
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About The Author


Stephen Wilkinson is a certified lean practitioner with an MBA and a BS in science from Worcester Polytechnic Institute. His improvement career started as an Army airborne combat engineer, where he turned around the failing performance of the brigade motor pool maintenance. After serving 4 years with the Army, he took an assignment as the Pringles potato chip lab and Pampers production manager at P&G. At Gillette, he managed projects at increasing leadership levels in industrial engineering and co-led the lean transformation of the Gillette facility. As a senior IE, he led improvements at Amgen in Rhode Island. The leaders at Amgen entrusted Stephen with his most significant projects, such as improving production cycle time and developing the breakthrough "Observe Analyze Improve," which eliminated 100,000 labor hours of non-value-adding effort. Stephen authors corporate playbooks on leading "Kaizen," "Standard Work," and "How to Observe Your Process for Improvement Opportunities." After training 1,200 professionals, saving millions of dollars, and implementing hundreds of improvements, Stephen now resides in Florida and serves as a lean consultant at Rapid Lean Coach. Steve can be reached for help at RapidLeanCoach@Gmail.com.
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Book Reviews

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Create a Continuous Flow of Improvements This book will help any organization learn to observe their process for improvement opportunities and to use lean methods to achieve that. Unlike the other books I read, it skips the lean theory and philosophy and describes the author's journey in learning to go straight to the shop floor and make improvements. It seems to be a step-by-step process of how the author eliminated 100,000 annual labor hours of unnecessawry work at one site. I intend to apply these steps and take the author up on his offer to do some free Team/ Zoom consulting to answer any questions. Read more