Creating Level Pull : A Lean Production-System Improvement Guide for Production-Control, Operations, and Engineering Professionals

Creating Level Pull shows you how to advance a lean manufacturing transformation from a focus on isolated improvements to improving the entire plantwide production system by implementing a lean production control system.

"The workbook is unique because it is a step-by-step case study on how to implement a level, pull-based production control system,” says author Art Smalley. "This is a new step towards ‘system kaizen that is not yet well understood outside of Toyota."

The lean efforts at most companies focus on "point kaizen" (e.g., reducing set up times, implementing 5S, etc.) that improves a small portion of the value stream running from raw materials to finished products. Or they focus on "flow kaizen" that improves the entire value stream for one product family. Creating Level Pull shows how companies can make the leap to "system kaizen" by introducing a lean production control system that ties together the flows of information and materials supporting every product family in a facility. With this system in place, each production activity requests precisely the materials it needs from the previous activity and demand from the customer is leveled to smooth production activities throughout the plant.

"A truly lean production-control system that rigorously controls production at every step and levels demand from the customer has proved a great challenge for most firms," said Jim Womack, "but Art gives you all the knowledge needed to succeed."

Acknowledgements
Foreword
Introduction

Part 1 : Getting Started
Part 2 : Matching Production-System Capability to Demand
Part 3 : Creating the Pacemaker
Part 4 : Controlling Production Upstream
Part 5 : Expanding the System
Part 6 : Sustaining and Improving

Conclusion
About the Author
Appendix
References