When was the last time your company improved productivity from 20 percent to 60 percent-in only four days? Or cut inventory by 50 percent in the same amount of time? Remarkable results like these were delivered by teams of employees and those who participated in the Association for Manufacturing Excellence Kaizen BlitzSM events. Using the Kaizen Blitz, employees learned how to work as a team to tackle problems from the shop floor and, most importantly, how to solve them quickly. That's what The Kaizen Blitz can teach you. Simply translated as "continuous improvement," kaizen is a highly focused process aimed at producing incremental performance improvements in narrowly targeted areas. The Kaizen Blitz is a powerful technique that delivers breakthrough improvements throughout an organization-fast. This book will show you how the Kaizen Blitz works and how to bring the extraordinary benefits of this approach to your company. Coauthored by executives of the AME, the book provides a frank discussion of what kaizen will and won't do, the preparation necessary, obstacles to be wary of, and the results you can expect. The Kaizen Blitz involves everyone across an organization-managers and workers alike. 44t is a low-cost, hands-on process, where all team members are equal and everyone gets their hands dirty. This thorough guide explains how your company can put together your own Kaizen Blitz teams to rapidly develop, test, and refine solutions to problems, leaving a new process in place in just a few days. It outlines how employees can work side by side to implement the best of their ideas for reaching common business goals, such as inventory reduction, capacity expansion, cost reduction, and leveraging capital investments. You will discover how the application of a few simple tools in a straightforward, common-sense approach can bring about real and profound change, provided that management is fully committed and ready to lead the process. In addition, the authors of this important book:* Help you determine whether your organization is ready to attempt the Kaizen Blitz* Outline what you need for an initial Kaizen Blitz project-and what to avoid* Explain why software package-driven process change has limitations* Cite results and applications in top U.S. manufacturers. If you are committed to adopting lean manufacturing; if you want an effective tool to address specific problems in your company; if you need radical change to happen now, The Kaizen Blitz will deliver beyond your highest expectations. The Association for Manufacturing Excellence has pioneered a powerful version of kaizen-a process for achieving continuous improvement in an organization-called the Kaizen Blitz.SM This book will show you how to use this remarkable tool to deliver breakthrough improvements in your company in areas like productivity, inventory reduction, capacity expansion, and much more. You'll learn how to assemble a kaizen team that will determine solutions to your company's specific problems by designing new systems, correcting mistakes quickly and moving on, running and refining procedures, and ultimately demonstrating a new process in place in just a few days. You'll also read about top U.S. manufacturers who have successfully used the Kaizen Blitz to bring about radical, positive change. If your company is ready to achieve dramatic results by implementing new processes-not just proposed, but in place and functioning-in a matter of days, the Kaizen Blitz is the way to make it happen.

Every day companies leave billions of dollars in invisible, unrealized savings on the table because of poor supply chain management practices. Now supply management experts Dave Nelson, Patricia E. Moody, and Jonathan Stegner show not only how leading companies recoup these savings through their mastery of target costing, value engineering, and supplier development, but how supply chain management -- the discipline of acquiring and moving material -- has become a manufacturing company''s hottest competitive weapon. Based on a survey of 247 purchasing managers and more than 1,000 hours of interviews and on-site visits, the authors have selected ten top firms whose supply management pioneers excel at twenty "best practices." With cases and stories, Nelson, Moody, and Stegner show how these leading-edge purchasing departments at American Express, SmithKline Beecham, DaimlerChrysler, Harley-Davidson, Honda of America, IBM, John Deere, Whirlpool, Flextronics, and Sun Microsystems have put into place pathbreaking processes and procedures. Here, for example, described in step-by-step detail, are Chrysler''s SCORE program and Honda''s strategic sourcing strategy that saved the companies billions. The book also includes a crucial section on the next stage of supplier development that will involve the sourcing and allocation of ideas as well as materials. The authors provide concrete, practical steps to improvement that any supply chain manager can take to successfully implement these best practices. The Purchasing Machine will be required reading for logistics, purchasing, and procurement managers in hundreds of thousands of companies. The authoritative nature of the authors'' source material is certain to make this the single most important and practical reference on best purchasing practices for years to come.

How will autonomous agents, emergent systems, and chaos theory change the way we live and work in the twenty-first century? As today''s manufacturing and production systems grow increasingly complex, tomorrow''s science of complexity will produce paradoxically simple solutions, argue technology experts Patricia Moody and Richard Morley in this astonishing vision of the year 2020. Containing both cutting-edge insights and simple truths that provide a roadmap to the future of business -- and illustrated by case examples from such companies as Motorola, Honda, GM, Solectron, Intel, Silicon Graphics, Modicon, Flavors, NeXT, Japanese Railway, and Andover Controls -- The Technology Machine challenges readers to understand the spirit and core drivers of growth: technology, knowledge, and individual excellence. By combining rigorous research with their extensive experience with technology advances that have changed industry, Moody and Morley are able to supply simple guidelines for future growth and detail their keen vision of future systems, leaders, and workers. They isolate the three bad business habits at the root of manufacturing problems today -- shortsightedness, restrictive structures, and unbalanced improvement fads -- show how to break them, and supply four infallible predictors of the types of breakthrough technologies that will come to dominate the world of the future. In that world, customers and suppliers are linked by real-time, online systems; business is driven by customer-designed, point-of-consumption replication of product; and a wide gap grows between "The Island of Excellence" organization of the future -- with its holistic approach, including two-year apprenticeships, uniforms, and morning exercises -- and "The Others," the non-elite, sweatshop-like, breakeven companies of the past. The book is eloquent, original, and essential reading for managers in every area of business and industry.

How will autonomous agents, emergent systems, and chaos theory change the way we live and work in the twenty-first century? As today's manufacturing and production systems grow increasingly complex, tomorrow's science of complexity will produce paradoxically simple solutions, argue technology experts Patricia Moody and Richard Morley in this astonishing vision of the year 2020.Containing both cutting-edge insights and simple truths that provide a roadmap to the future of business -- and illustrated by case examples from such companies as Motorola, Honda, GM, Solectron, Intel, Silicon Graphics, Modicon, Flavors, NeXT, Japanese Railway, and Andover Controls -- The Technology Machine challenges readers to understand the spirit and core drivers of growth: technology, knowledge, and individual excellence.By combining rigorous research with their extensive experience with technology advances that have changed industry, Moody and Morley are able to supply simple guidelines for future growth and detail their keen vision of future systems, leaders, and workers. They isolate the three bad business habits at the root of manufacturing problems today -- shortsightedness, restrictive structures, and unbalanced improvement fads -- show how to break them, and supply four infallible predictors of the types of breakthrough technologies that will come to dominate the world of the future. In that world, customers and suppliers are linked by real-time, online systems; business is driven by customer-designed, point-of-consumption replication of product; and a wide gap grows between "The Island of Excellence" organization of the future -- with its holistic approach, including two-year apprenticeships, uniforms, and morning exercises -- and "The Others," the non-elite, sweatshop-like, breakeven companies of the past. The book is eloquent, original, and essential reading for managers in every area of business and industry.

Most manufacturing companies with batch-and-queue "push" production systems have been blindsided by today's consumer who expects quality products and services delivered on demand and customized to individual taste. In The Perfect Engine, manufacturing experts Anand Sharma and Patricia E. Moody describe for the first time how leading "pull" production pioneers build to order by reducing inventory, decreasing cycle time, minimizing floor space, and eliminating waste. Drawing on scores of examples and detailed case studies of three leaders in the demand economy field -- Maytag, Pella, and Mercedes-Benz -- Sharma and Moody demonstrate how these companies achieved astonishing results using the pathbreaking LeanSigmaSM Transformation. Combining lean production and quality elements from the famous Six Sigma process, LeanSigma produces annual productivity gains of 15 percent to 20 percent. In addition, the authors show, inventory turns more than quadruple; cycle times drop by more than 70 percent; and floor space reductions of 30 percent to 50 percent are not uncommon. Sharma and Moody provide immensely readable explanations of key technical aspects of the process--for example, how cell-based one-piece flow can replace batch-and-queue with dramatically improved lead times and inventory turnover. A chapter on a revolutionary design technique the authors call Design for LeanSigma or 3P (product and production preparation) shows how to build flexibility into the product design and the production systems at very low risk, which will be especially helpful when forecasts and customer orders deviate from original projections, as they usually do. Further, the Design for LeanSigma method is devised to produce profitability at short-term volume projections, which makes it a perfect tool for the new demand economy. Essential, timely, and important, The Perfect Engine is perfect reading for this new manufacturing era.

When was the last time your company improved productivity from 20 percent to 60 percent-in only four days? Or cut inventory by 50 percent in the same amount of time? Remarkable results like these were delivered by teams of employees and those who participated in the Association for Manufacturing Excellence Kaizen BlitzSM events. Using the Kaizen Blitz, employees learned how to work as a team to tackle problems from the shop floor and, most importantly, how to solve them quickly. That's what The Kaizen Blitz can teach you. Simply translated as "continuous improvement," kaizen is a highly focused process aimed at producing incremental performance improvements in narrowly targeted areas. The Kaizen Blitz is a powerful technique that delivers breakthrough improvements throughout an organization-fast. This book will show you how the Kaizen Blitz works and how to bring the extraordinary benefits of this approach to your company. Coauthored by executives of the AME, the book provides a frank discussion of what kaizen will and won't do, the preparation necessary, obstacles to be wary of, and the results you can expect. The Kaizen Blitz involves everyone across an organization-managers and workers alike. 44t is a low-cost, hands-on process, where all team members are equal and everyone gets their hands dirty. This thorough guide explains how your company can put together your own Kaizen Blitz teams to rapidly develop, test, and refine solutions to problems, leaving a new process in place in just a few days. It outlines how employees can work side by side to implement the best of their ideas for reaching common business goals, such as inventory reduction, capacity expansion, cost reduction, and leveraging capital investments. You will discover how the application of a few simple tools in a straightforward, common-sense approach can bring about real and profound change, provided that management is fully committed and ready to lead the process. In addition, the authors of this important book:* Help you determine whether your organization is ready to attempt the Kaizen Blitz* Outline what you need for an initial Kaizen Blitz project-and what to avoid* Explain why software package-driven process change has limitations* Cite results and applications in top U.S. manufacturers. If you are committed to adopting lean manufacturing; if you want an effective tool to address specific problems in your company; if you need radical change to happen now, The Kaizen Blitz will deliver beyond your highest expectations. The Association for Manufacturing Excellence has pioneered a powerful version of kaizen-a process for achieving continuous improvement in an organization-called the Kaizen Blitz.SM This book will show you how to use this remarkable tool to deliver breakthrough improvements in your company in areas like productivity, inventory reduction, capacity expansion, and much more. You'll learn how to assemble a kaizen team that will determine solutions to your company's specific problems by designing new systems, correcting mistakes quickly and moving on, running and refining procedures, and ultimately demonstrating a new process in place in just a few days. You'll also read about top U.S. manufacturers who have successfully used the Kaizen Blitz to bring about radical, positive change. If your company is ready to achieve dramatic results by implementing new processes-not just proposed, but in place and functioning-in a matter of days, the Kaizen Blitz is the way to make it happen.

Every day companies leave billions of dollars in invisible, unrealized savings on the table because of poor supply chain management practices. Now supply management experts Dave Nelson, Patricia E. Moody, and Jonathan Stegner show not only how leading companies recoup these savings through their mastery of target costing, value engineering, and supplier development, but how supply chain management -- the discipline of acquiring and moving material -- has become a manufacturing company''s hottest competitive weapon. Based on a survey of 247 purchasing managers and more than 1,000 hours of interviews and on-site visits, the authors have selected ten top firms whose supply management pioneers excel at twenty "best practices." With cases and stories, Nelson, Moody, and Stegner show how these leading-edge purchasing departments at American Express, SmithKline Beecham, DaimlerChrysler, Harley-Davidson, Honda of America, IBM, John Deere, Whirlpool, Flextronics, and Sun Microsystems have put into place pathbreaking processes and procedures. Here, for example, described in step-by-step detail, are Chrysler''s SCORE program and Honda''s strategic sourcing strategy that saved the companies billions. The book also includes a crucial section on the next stage of supplier development that will involve the sourcing and allocation of ideas as well as materials. The authors provide concrete, practical steps to improvement that any supply chain manager can take to successfully implement these best practices. The Purchasing Machine will be required reading for logistics, purchasing, and procurement managers in hundreds of thousands of companies. The authoritative nature of the authors'' source material is certain to make this the single most important and practical reference on best purchasing practices for years to come.

How will autonomous agents, emergent systems, and chaos theory change the way we live and work in the twenty-first century? As today''s manufacturing and production systems grow increasingly complex, tomorrow''s science of complexity will produce paradoxically simple solutions, argue technology experts Patricia Moody and Richard Morley in this astonishing vision of the year 2020. Containing both cutting-edge insights and simple truths that provide a roadmap to the future of business -- and illustrated by case examples from such companies as Motorola, Honda, GM, Solectron, Intel, Silicon Graphics, Modicon, Flavors, NeXT, Japanese Railway, and Andover Controls -- The Technology Machine challenges readers to understand the spirit and core drivers of growth: technology, knowledge, and individual excellence. By combining rigorous research with their extensive experience with technology advances that have changed industry, Moody and Morley are able to supply simple guidelines for future growth and detail their keen vision of future systems, leaders, and workers. They isolate the three bad business habits at the root of manufacturing problems today -- shortsightedness, restrictive structures, and unbalanced improvement fads -- show how to break them, and supply four infallible predictors of the types of breakthrough technologies that will come to dominate the world of the future. In that world, customers and suppliers are linked by real-time, online systems; business is driven by customer-designed, point-of-consumption replication of product; and a wide gap grows between "The Island of Excellence" organization of the future -- with its holistic approach, including two-year apprenticeships, uniforms, and morning exercises -- and "The Others," the non-elite, sweatshop-like, breakeven companies of the past. The book is eloquent, original, and essential reading for managers in every area of business and industry.

How will autonomous agents, emergent systems, and chaos theory change the way we live and work in the twenty-first century? As today's manufacturing and production systems grow increasingly complex, tomorrow's science of complexity will produce paradoxically simple solutions, argue technology experts Patricia Moody and Richard Morley in this astonishing vision of the year 2020.Containing both cutting-edge insights and simple truths that provide a roadmap to the future of business -- and illustrated by case examples from such companies as Motorola, Honda, GM, Solectron, Intel, Silicon Graphics, Modicon, Flavors, NeXT, Japanese Railway, and Andover Controls -- The Technology Machine challenges readers to understand the spirit and core drivers of growth: technology, knowledge, and individual excellence.By combining rigorous research with their extensive experience with technology advances that have changed industry, Moody and Morley are able to supply simple guidelines for future growth and detail their keen vision of future systems, leaders, and workers. They isolate the three bad business habits at the root of manufacturing problems today -- shortsightedness, restrictive structures, and unbalanced improvement fads -- show how to break them, and supply four infallible predictors of the types of breakthrough technologies that will come to dominate the world of the future. In that world, customers and suppliers are linked by real-time, online systems; business is driven by customer-designed, point-of-consumption replication of product; and a wide gap grows between "The Island of Excellence" organization of the future -- with its holistic approach, including two-year apprenticeships, uniforms, and morning exercises -- and "The Others," the non-elite, sweatshop-like, breakeven companies of the past. The book is eloquent, original, and essential reading for managers in every area of business and industry.

Most manufacturing companies with batch-and-queue "push" production systems have been blindsided by today's consumer who expects quality products and services delivered on demand and customized to individual taste. In The Perfect Engine, manufacturing experts Anand Sharma and Patricia E. Moody describe for the first time how leading "pull" production pioneers build to order by reducing inventory, decreasing cycle time, minimizing floor space, and eliminating waste. Drawing on scores of examples and detailed case studies of three leaders in the demand economy field -- Maytag, Pella, and Mercedes-Benz -- Sharma and Moody demonstrate how these companies achieved astonishing results using the pathbreaking LeanSigmaSM Transformation. Combining lean production and quality elements from the famous Six Sigma process, LeanSigma produces annual productivity gains of 15 percent to 20 percent. In addition, the authors show, inventory turns more than quadruple; cycle times drop by more than 70 percent; and floor space reductions of 30 percent to 50 percent are not uncommon. Sharma and Moody provide immensely readable explanations of key technical aspects of the process--for example, how cell-based one-piece flow can replace batch-and-queue with dramatically improved lead times and inventory turnover. A chapter on a revolutionary design technique the authors call Design for LeanSigma or 3P (product and production preparation) shows how to build flexibility into the product design and the production systems at very low risk, which will be especially helpful when forecasts and customer orders deviate from original projections, as they usually do. Further, the Design for LeanSigma method is devised to produce profitability at short-term volume projections, which makes it a perfect tool for the new demand economy. Essential, timely, and important, The Perfect Engine is perfect reading for this new manufacturing era.