e-Book
Sustaining the Gain - e-Book
Lonnie and Joe Dager converted his "Sustaining the Gains" podcast to a book of the same name. Register below for immediate access to the book.
Presentations
Copies of slides used in Lonnie's presentations.
Industry Week Best Plants Conference
This is a presentation Lonnie made at the Industry Week Best Plants Conference in Cleveland on the Advanced Continuous Improvement Track.
The title of the presentation was, “Are you involved in Continous Improvement or Continuous Catch-up?”.
Register below for immediate access to the slides.
iSixSigma Annual Energy Conference, 2009
This is a presentation Lonnie made at the 2009 iSixSigma Annual Energy Conference in Houston. The title of the presentation was,
“Why Has Lean Manufacturing Not Been More Widely Applied in the Continuous Process Industries….especially Oil Refining.”
Register below for immediate access to the slides.
iSixSigma Annual Energy Conference, 2010
This is a presentation Lonnie made at the 2010 iSixSigma Annual Energy Conference in Houston. He led a Master Class Workshop
attended by Senior Managers in the Energy Field. The title of the Master Class Workshop was: "The Four Indispensable Tools of a Lean
Enterprise." As part of the Master Class Workshop, using the slides as a background, Lonnie guided the Managers into the construction of a Survey
that they could use to evaluate one of the cultural dimensions studied in the presentation. Register below for immediate access to the slides.
ASQ
This is a presentation Lonnie made for ASQ and it not only focuses on “What is Lean” but how it has wide applicability in
not only the world of discrete parts
manufacturing but also the businesses of continuous process industries, service sectors and also charities.
Register below for immediate access to the slides.
White Papers
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JIT - Summary
Summary
These three operating principles, integrated, allow us to provide high levels of
OTD, with a minimum production lead time while reducing waste and reducing
the cost to produce.
(Read more...)
Takt
Summary
Takt is a technique to execute the system of heijunka.
It is the concept of supplying the customer at their demand rate, normalized to our available time.
(Read more...)
FLOW – In Lean Systems
Summary
The key element to make the just in time manufacturing system function is to
have a process of continuous flow. Since continuous flow is not a practical
reality, the lean approach is to keep the product moving as much as is practical
and continuously work to improve the lead time. To do this we can attack the 8
obstacles to flow with the “Seven Techniques to Improve Flow”.
(Read more...)
Pull Production Systems
Summary
Pull production is a tactic which is required to make JIT manufacturing possible.
It will allow you to attain high levels of customer service while minimizing the
waste of inventory. It has proven itself to be a superior system to its counterpart,
push production.
(Read more...)
Five Things You Can Do to Lean Your Company
Summary
Five tasks in two days can set lean in motion.
(Read more...)
The Real Power Behind the Toyota Production System
Summary
The powers of the TPS are management’s commitment to and creation of a culture which:
- shows respect for people and
- promotes continuous improvement.
(Read more...)
Respect for People
Summary
Toyota’s concept of respect for people is lost on a lot of us Westerners. Not
totally lost of course, but its meaning is significantly diluted. The Toyota concept
goes beyond what we typically call respectful behavior. It has at its foundation a
faith in the human element and a belief in the abundance around us.
(Read more...)
Continuous Improvement
Summary
The concept of continuous improvement actually lies on a continuum which at is
lowest levels is simply catch-up work; it then passes through reactionary
improvement activities; and its refinement is known as Toyota Continuous
Improvement.
(Read more...)
The Uneasy Dance Between IT and Lean
Summary
There is an uneasy dance going on between Lean practitioners and IT personnel.
It is not clear if the Lean folks want or think they need it...
(Read more...)
Management Commitment
Summary
Lack of management commitment is the largest reason cultural changing initiatives fall short of their objectives.
We have a way to quantify this important characteristic and...
(Read more...)
TPS - A Culture of Responsibility
Summary
In my book, “How To Implement Lean Manufacturing”, I characterize Toyota as a responsible company. Herein I will detail,
specifically, how and why I draw that conclusion. In so doing I hope you will be able to not only see the power of this
crucial behavior but also be able to assess the “level of responsibility” of your company and begin the process to elevate
it on the responsibility continuum....
(Read more...)
How To Create Precisely What You Do Not Want
Summary
Lonnie was asked to write a feature article for Focus.com and wrote this article about goals and how
their very creation, if you are not careful, can be extremely counterproductive. So you get "Precisely
what you do not want." This sounds odd...paradoxical...but it is extremely common and may be
affecting you as well...
(Read more...)
Lean Articles for iSixSigma Magazine
Summary
The e-Magazine, iSixSigma commissioned Lonnie to write 5 articles on Lean Culture. In this series Lonnie goes
through how you can manage your culture and "sustain the gains" by specifically addressing four cultural
principles. In question format, they are:
- Do you have a clear statement of purpose for the business?
- Do you have Lean leadership?
- Is your business philosophy based on respect for people?
- Do you have a real, functioning continuous improvement process?
(Read the articles...)
Loyalists, Lurkers and Laggards
Summary
One day, in his not-so-spare time, Lonnie was ruminating on one aspect of implementing lean - how to get the
critical mass engaged. He wrote this article which to some is a bit funny, but unfortunately it is all too true.
Read it and tell him what you think.
(Read more...)
