Book: Lean Production Simplified

Several reliable sources recommended Lean Production Simplified by Pascal Dennis as a firm starting point on my journey for Lean manufacturing knowledge. The Society of Manufacturing Engineers (SME) placed the book on the reading list for Lean certification. This Shingo prize winning book bills itself as “A plain language guide to the world’s most powerful production system.” Dennis delivers providing an valuable overview of lean production system history and concepts. In Chapter 1: The Birth of Lean Production, Pascal Dennis provides historical context to the Toyota Production System. He follows the evolution from craft production to mass production introducing the dysfunctional elements of both. He describes the tough economical environment of Japan in the 1950s which provided the impetus for Lean. This information gives us a nuanced, historical understanding that simply learning about Lean activities and tools could not provide. The book proceeds to describe the lean production system in the second chapter. Since Lean Production Simplified is only slightly over 100 pages, Dennis introduces the concepts concisely, if not just briefly. Many books provide very in-depth analysis of customer focus or systems thinking, so I really did not consider brevity on specific subjects a negative. The “House of Lean Production” diagrams are a helpful visual reminder of the Lean activities Dennis describes in the next chapters. Pascal Dennis transforms his experience with Toyota into clear information. The book continues by dutifully describing core concepts of Lean such as Standardized Work, JIT, and Jidoka. Lean Production Simplified helps the reader become conversant with a otherwise dizzying list of terminologies. The final three chapters present the concepts of Involvement, Hoshin Planning, and Lean Culture. These concepts are considerably more nebulous. I understand why this information naturally falls to the end of the book, but I consider these foundational concepts without which the House of Lean cannot stand. Understanding and building strong organizational cultures is a difficult task many Lean texts (and managers) simply wish to ignore. I was happy to see a significant level of focus by Dennis. I have only minor reservations or complaints. I would like to see more information geared towards job shop/high-mix, low volume manufacturing (HMLV). Many of the tools discussed have applicability to the HMLV environment only after significant adaptation. I realize this might betray the simple guide mission of the book, but HMLV is my background. As Dennis presented each Lean activity/tool, I consistently wished a case study described the concept through the lens of experience. The case study method enhances understanding through context. Several prominent business texts take the method farther and develop fictional stories to convey otherwise difficult ideas. The book absolutely delivers as a plain language guide. I strongly recommend Lean Production Simplified.