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Publications

The Lean Practitioner’s Field Book: Proven, Practical, Profitable and Powerful Techniques for Making Lean Really Work

 Features

  • Details the five Lean Practitioner levels
  • Includes quizzes and criteria for each level
  • Distinguishes between the Kaizen event approach and the Lean system-level approach
  • Explains how to implement Lean tools with an emphasis on line balancing
  • Explores the difference between station balancing and baton zone

Summary

While there are numerous Lean Certification programs, most companies have their own certification paths for Lean Specialists and Masters where expert status is bestowed after employees participate in or lead a certain number of kaizen events. Arguing that the number of kaizen events should not determine a person’s expert status, The Lean Practitioner’s Field Book: Proven, Practical, Profitable and Powerful Techniques for Making Lean Really Work outlines a true learning path for anyone seeking to understand essential Lean principles. The book includes a plethora of examples drawn from the personal experiences of its many well-respected and award-winning contributors. These experts break down Lean concepts to their simplest terms to make everything as clear as possible for Lean practitioners. A refresher for some at times, the text provides thought-provoking questions with examples that will stimulate learning opportunities. Introducing the Lean Practitioner concept, the book details the five distinct Lean Practitioner levels and includes quizzes and criteria for each level. It highlights the differences between the Kaizen event approach and the Lean system level approach as well as the difference between station balancing and baton zone. This book takes readers on a journey that begins with an overview of Lean principles and culminates with readers developing professionally through the practice of self-reliance. Providing you with the tools to implement Lean tools in your organization the book includes discussions and examples that demonstrate how to transition from traditional accounting methods to a Lean accounting system. The book outlines an integrated, structured approach which is combined with a proven business strategy to help ensure a successful and sustainable transformation of your organization.

One Piece Flow vs. Batching

Features

  • Identifies the eight root causes of batching
  • Outlines the advantages of one-piece flow versus batching
  • Describes how batching drives the eight wastes
  • Includes case studies and examples that illustrate why one-piece flow is better than batching

Summary

Although batching often appears more efficient than one-piece flow for individual tasks, the practice creates waste for other parts of the organization that more than offset its perceived benefits. A silent productivity killer, batching is an extremely difficult mindset to overcome and, as a result, numerous Lean initiatives have been destroyed by it.

This book argues the case for one-piece flow over batching. It identifies the eight root causes of batching, the wastes created from batching, how batching drives the eight wastes, and the advantages of one-piece flow.

One-Piece Flow vs. Batching: A Guide to Understanding How Continuous Flow Maximizes Productivity and Customer Value provides concrete arguments as to why batching, while sometimes necessary, is never the most efficient solution for most processes. It explains why flow, especially one-piece flow or continuous flow, should always be your ultimate objective when driving for increased productivity in any process.

Using case studies to illustrate how to channel current mindsets toward one-piece flow as the preferred operation, the book is designed to support anyone involved in continuous improvement activities. It provides the tools and understanding you will need to overcome resistance to implementing flow and, in particular, one-piece flow processes—whether it be on the factory floor or in a banking office.

Card-Based Control Systems for a Lean Work Design: The Fundamentals of Kanban, ConWIP, POLCA, and COBACABANA

Features

  • Takes a different approach than most other books on the subject—as it starts with an introduction to the control problem, not the control solution
  • Discusses all major card-based control systems
  • Introduces a new system developed for high-variety shops that extends card-based control to providers of made-to-order, customized products
  • Outlines a unique approach for estimating due dates using cards

Summary

Many shops have simplified their production control by using card-based systems such as kanban and Constant Work-in-Process (ConWIP). Although these systems provide a simple and highly effective visual approach for controlling manufacturing and service operations, all too many shops struggle with failed implementations or achieve results that fall below expectations. These outcomes can be attributed to a poor fit between the actual control problem and the solution applied.

This book takes a different approach to most other books on the subject—as it starts with an introduction to the control problem, instead of the control solution. Card-Based Control Systems for a Lean Work Design outlines how the problems encountered in typical manufacturing shops and service providers can be characterized, which allows for improved problem diagnosis.

The first four chapters of the book lay the foundations for problem diagnosis. The next three chapters then discuss, in sequence, each of the three “traditional” card-based control systems: kanban, ConWIP, and Paired-cell Overlapping Loops of Cards with Authorization (POLCA). The book explains how each of these card-based control systems works and identifies the specific type of control problem to which each system applies.

The next two chapters focus on Control of Balance by Card-Based Navigation (COBACABANA), a system developed for high-variety shops producing made-to-order, customized products. This is the first book to discuss this novel approach, which includes the use of cards to estimate due dates or delivery time allowances.

The book closes with a framework that provides guidance on which system to apply. This framework contrasts the control problem with the control solution. The potential of combining card-based systems is also discussed to create a nested solution.

Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System

Date: December 21, 2010 | ISBN-10: 143981385X | ISBN-13: 978-1439813850

Winner of a 2012 Shingo Research and Professional Publication Award

This practical guide for healthcare executives, managers, and frontline workers, provides the means to transform your enterprise into a High-Quality Patient Care Business Delivery System. Designed for continuous reference, its self-contained chapters are divided into three primary sections:

  • Defines what Lean is and includes some interesting history about Lean not found elsewhere.
  • Describes and explains the application of each Lean tool and concept organized in their typical order of use.
  • Explains how to implement Lean in various healthcare processes—providing examples, case studies, and valuable lessons learned

This book will help to take you out of your comfort zone and provide you with new ways to extend value to your customers. It drives home the importance of the Lean Six Sigma journey. The pursuit of continuous improvement is a journey with no end. Consequently, the opportunities are endless as to what you and your organization can accomplish. Forty percent of the authors’ profits from this book will be donated to help the homeless through two Baltimore charities.

Praise for the Book

“… well-timed and highly informative for those committed to creating deep levels of sustainable change in healthcare.”
— Peter B. Angood, MD, FACS, FCCM, Senior Advisor – Patient Safety, in National Quality Forum

“… the most practical and healthcare applicable book I have ever read on LEAN thinking and concepts.”
— Gary Shorb, CEO, Methodist Le Bonheur Healthcare

“… an essential reference in the library of all healthcare leaders interested in performance improvement.”
— Lee M. Adler, DO, VP, Quality and Safety Innovation & Research, Florida Hospital, Orlando; Associate Professor, University of Central Florida College of Medicine

“A must read for all Leadership involved in healthcare. … I can see reading this book over and over.”
Brigit Zamora, BSN, RN, CPAN, CAPA, Administrative Nurse Manager, Florida Hospital, Orlando

Leveraging Lean in Outpatient Clinics: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation

Publication Date: December 3, 2014 by Productivity Press, Content: 360 Pages |  104 B/W Illustrations, Author(s): Charles Protzman, Joyce Kerpchar, George Mayzell, MD, MBA, FACP

Features

  • Provides a functional understanding of Lean processes and quality improvement techniques for primary care, GI, and preadmission testing clinics
  • Identifies solutions specific to the needs of each outpatient facility
  • Includes examples, stories, case studies, and lessons learned from successful Lean implementations
  • Presents detailed descriptions of Lean tools and methodologies

Summary

This book is part of a series of titles that are a spin-off of the Shingo Prize-winning book Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System. Each book in the series focuses on a specific aspect of healthcare—including emergency departments, medical laboratories, outpatient clinics, ancillary services, and surgical services—that has demonstrated significant process and quality improvements after a Lean implementation.
Because ambulatory care settings play a significant role in the healthcare delivery system, it is important to understand how Lean concepts and tools can be used to deliver high-quality, cost-effective care. Leveraging Lean in Outpatient Clinics: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation provides a functional understanding of Lean processes and quality improvement techniques in an outpatient clinic environment.

This book is an ideal guide for healthcare executives, leaders, process improvement team members, and inquisitive frontline workers who want to implement and leverage Lean in outpatient clinical settings. Supplying detailed descriptions of Lean tools and methodologies, it identifies powerful Lean solutions specific to the needs of outpatient facilities.

The first section provides an overview of Lean concepts, tools, methodologies, and applications. The second section focuses on the application of Lean in the outpatient clinic environment. It presents illustrative examples of Lean deployments in primary care, GI, and preadmission testing clinics. The examples provide broad content which can be readily transferable to other outpatient clinic settings.

Illustrating leadership’s role in achieving departmental goals, this book will provide you with a well-rounded understanding of how Lean can be applied to achieve significant improvements throughout the complete continuum of care.

Leveraging Lean in the Emergency Department: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation

Publication Date: December 3, 2014 by Productivity Press, Content: 370 Pages |  107 B/W Illustrations, Author(s): Charles Protzman, Joyce Kerpchar, George Mayzell, MD, MBA, FACP

Features

  • Supplies a functional understanding of Lean emergency department processes and quality improvement techniques
  • Identifies solutions specific to the needs of the emergency department
  • Includes examples, case studies, and lessons learned from successful Lean deployments
  • Provides authoritative guidance on implementing Lean in the emergency department

Summary

This book is part of a series of titles that are a spin-off of the Shingo Prize-winning book Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System. Each book in the series focuses on a specific aspect of healthcare that has demonstrated significant process and quality improvements after a Lean implementation.

Emergency departments have become notorious for long wait times and questionable quality of care. By adopting Lean manufacturing concepts, hospitals can turn the emergency department into a valuable service for the hospital and the community it serves.

Leveraging Lean in the Emergency Department: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation supplies a functional understanding of Lean emergency department processes and quality improvement techniques. It is ideal for healthcare executives, leaders, process improvement team members, and inquisitive frontline workers who want to implement and leverage Lean.

Supplying detailed descriptions of Lean tools and methodologies, the book identifies powerful Lean solutions specific to the needs of the emergency department. The first section provides an overview of Lean concepts, tools, methodologies, and applications.

The second section focuses on the application of Lean in the emergency department within the confines of the hospital or clinic. Presenting numerous examples, stories, case studies, and lessons learned, it examines the normal operation of each area in emergency departments and highlights the areas where typical problems occur.

Next, the book walks readers through various Lean initiatives and demonstrates how Lean tools and concepts have been used to achieve lasting improvements to processes and quality of care. It also supplies actionable blueprints that readers can duplicate or modify for use in their own institutions.

Illustrating leadership’s role in achieving departmental goals, this book will provide you with a well-rounded understanding of how Lean can be applied to achieve significant improvements throughout the entire continuum of care.

Leveraging Lean in Medical Laboratories: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation

Publication Date: December 3, 2014 by Productivity Press, Content: 330 Pages |  98 B/W Illustrations, Author(s): Charles Protzman, Joyce Kerpchar, George Mayzell, MD, MBA, FACP

Features

  • Provides a functional understanding of Lean processes and quality improvement techniques for the medical laboratory
  • Includes examples, stories, case studies, and lessons learned from successful Lean implementations
  • Supplies authoritative guidance on how to implement Lean in the laboratory
  • Illustrates the application of Lean tools and concepts in the medical laboratory environment

Summary

This book is part of a series of titles that are a spin-off of the Shingo Prize-winning book Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System. Each book in the series focuses on a specific aspect of healthcare that has demonstrated significant process and quality improvements after a Lean implementation.

Lean principles can help medical laboratories drive up efficiencies and quality without increasing costs or compromising quality. Leveraging Lean in Medical Laboratories: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation provides a functional understanding of Lean laboratory processes and quality improvement techniques.

This book is an ideal guide for healthcare executives, leaders, process improvement team members, and inquisitive frontline workers who want to implement and leverage Lean in medical laboratories. Supplying detailed descriptions of Lean tools and methodologies, it identifies powerful Lean solutions specific to the needs of the medical laboratory.

The first section provides an overview of Lean concepts, tools, methodologies, and applications. The second section focuses on the application of Lean in the laboratory environment. Presenting numerous examples, stories, case studies, and lessons learned, it examines the normal operation of each area in the lab environment and highlights the areas where typical problems occur.

Next, it walks readers through various Lean initiatives and demonstrates how Lean tools and concepts have been used to achieve lasting improvements to processes and quality of care. It also supplies actionable blueprints that readers can duplicate or modify for use in their own institutions.

Illustrating leadership’s role in achieving departmental goals, this book will provide you with a well-rounded understanding of how Lean can be applied to achieve significant improvements throughout the entire continuum of care.

Leveraging Lean in Surgical Services: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation

Publication Date: December 3, 2014 by Productivity Press, Content: 380 Pages |  119 B/W Illustrations, Author(s): Charles Protzman, Joyce Kerpchar, George Mayzell, MD, MBA, FACP

Features

  • Provides a functional understanding of Lean processes and quality improvement techniques for the surgical suite
  • Identifies solutions specific to the needs of surgical services
  • Includes case studies of actual Lean implementations and the tools used
  • Supplies how-to guidance on implementing Lean in the surgical suite
  • Illustrates powerful Lean tools and methodologies with examples, stories, case studies, and lessons learned

Summary

This book is part of a series of titles that are a spin-off of the Shingo Prize-winning book Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System. Each book in the series focuses on a specific aspect of healthcare that has demonstrated significant process and quality improvements after a Lean implementation.

The result of implementing Lean in the surgical suite is a powerful and proven mix that enables members of cross-functional teams to improve their processes, efficiency, and financial performance. Leveraging Lean in Surgical Services: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation provides a functional understanding of Lean processes and quality improvement techniques for the surgical department.

This book is an ideal guide for healthcare executives, leaders, process improvement team members, and inquisitive frontline workers who want to implement and leverage Lean in the surgical suite. Supplying detailed descriptions of Lean tools and methodologies, it identifies powerful solutions specific to the needs of surgical services.

The first section provides an overview of Lean concepts, tools, methodologies, and applications. The second section focuses on the application of Lean in the surgical services environment. Presenting numerous examples, stories, case studies, and lessons learned, it examines the normal operation of each area in the surgical suite and highlights the areas where typical problems occur.

Next, the book walks readers through various Lean initiatives and demonstrates how Lean tools and concepts have been used to achieve lasting improvements to processes and quality of care. It also introduces actionable blueprints that readers can duplicate or modify for use in their own institutions.

Illustrating leadership’s role in achieving departmental goals, this book will provide you with a well-rounded understanding of how Lean can be applied to achieve significant improvements throughout the entire continuum of care.

Leveraging Lean in Ancillary Hospital Services: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation

Publication Date: December 3, 2014 by Productivity Press, Content: 354 Pages |  106 B/W Illustrations, Author(s): Charles Protzman, Joyce Kerpchar, George Mayzell, MD, MBA, FACP

Features

  • Provides a functional understanding of Lean processes and quality improvement techniques for ancillary hospital services
  • Identifies solutions specific to the needs of hospital support and ancillary services departments
  • Includes examples, stories, case studies, and lessons learned from nutritional services, inpatient floors, pharmacy, and radiology
  • Supplies authoritative guidance on implementing Lean in hospital support departments
  • Describes powerful Lean tools and methodologies in detail

Summary

This book is part of a series of titles that are a spin-off of the Shingo Prize-winning book Leveraging Lean in Healthcare: Transforming Your Enterprise into a High Quality Patient Care Delivery System. Each book in the series focuses on a specific aspect of healthcare that has demonstrated significant process and quality improvements after a Lean implementation.

There are many departments within a hospital that support the primary function of caregiving and each can benefit from implementing Lean methodologies. Leveraging Lean in Ancillary Hospital Services: Creating a Cost Effective, Standardized, High Quality, Patient-Focused Operation provides a functional understanding of Lean processes and quality improvement techniques in nutritional services, inpatient floors, pharmacy, and radiology.

This book is ideal for healthcare executives, leaders, process improvement team members, and inquisitive frontline workers who want to implement and leverage Lean. Supplying detailed descriptions of Lean tools and methodologies, it identifies powerful Lean solutions specific to the needs of ancillary hospital services.

The first section provides an overview of Lean concepts, tools, methodologies, and applications. The second section focuses on the application of Lean in the ancillary hospital services environment. Presenting numerous examples, stories, case studies, and lessons learned, it examines the normal operation of each area in radiology, pharmacy, and nutritional services and highlights the areas where typical problems occur.

The case studies walk readers through various Lean initiatives and demonstrate how Lean tools and concepts have been used to achieve lasting improvements to processes and quality of care. It also introduces actionable blueprints that readers can duplicate or modify for use in their own institutions.

Illustrating leadership’s role in achieving departmental goals, this book will provide you with a well-rounded understanding of how Lean can be applied to achieve significant improvements throughout the entire continuum of care.