Trenches - A Lean Transformation Novel: A real world look at deploying the Improvement Kata into your organization - Paperback

by Jeffrey K. Liker (Author), James K. Franz (Author)

Lean transformation mean different things to different companies, consulting firms, and even "thought leaders." Some view lean as a toolkit to eliminate waste to be implemented mechanically as one would install software on a computer. The authors of this book view it as a process of engaging people throughout the organization in a new way of managing to deliver exceptional customer value. Those who have been in the trenches often feel like it is the front lines of a civil war between different factions with different points of view. The best way to experience this social and political process, short of living it, is through a good business novel. In this book, Franz and Liker immerse you in a world where you can begin to learn the basics by walking with the people at Amalgamated and Shiloh as they grapple with the challenges, trials, and tribulations surrounding lean as well as business transformation in general. This in-depth case study was built on a collective sixty years of up close, in depth experiences from both Franz and Liker as they've worked with companies around the globe in their transformation efforts. As you will learn in Trenches, this is a full-contact sport. You'll probably see some aspects of yourself and your company in these pages. The companies live through distinct phases of lean transformation, not unlike what many companies experience. There is a honeymoon period with an experienced lean coach who guides Amalgamated through a deep transformation of one area of their plant with stunning results. Those involved in the transformation learn to see the transformation as systemic focused on improved processes and development of people. They grow and blossom. Then just as they are preparing to spread this profound knowledge they are merged with Shiloh and their mechanistic-oriented lean black belts take over virtually destroying what Amalgamated started. As the company performance plummets new leadership emerges and a new, deeper approach to developing people is introduced-Toyota kata. Leaders learn practice routines to develop a true kaizen mindset. Regardless of where you are in your own journey, this book is written to give you support where and when you need it and to offer a glimpse into an organization as it struggles, falls, gets up again and keeps on trying. It does this because, as we always say, that's how you learn on your journey.

Author Biography

Shingo Prize-winning author, researcher, and globally recognized lean expert, James K. Franz has over 30 years of manufacturing, engineering, and service experience and learned Lean as a Toyota Production Engineer in Japan. He started at the NUMMI plant in California, moved to Motomachi in Japan, repatriating to support Toyota's launch of their second factory in Kentucky. In 2004 Jim went to work with twelve-time Shingo Prize-winning author Dr. Jeffrey Liker as a Senior Lean Consultant. In 2008 he partnered with Dr. Liker to co-found the Toyota Way Academy. His work has taken him to over 50 countries and innumerable companies around the globe including Bosch, the U.S. Air Force, Exxon Mobil, AMCOR, Android Industries, Applied Materials, Benteler Automotive, Case New Holland, Caterpillar, Chicago Metallic, Dakkota, Fisher Coachworks, Grand Rapids Chair, Henry Ford Health System, Hertz, JLG, MENLO Logistics, Rio Tinto, SAF Holland, Continental VDO, Visteon, WABCO, and others. He also taught for the University of Michigan's Center for Professional Development's Lean Certification course and has guest lectured around the world as a recognized expert on Lean and Continuous Improvement Cultures and transformation. Dr. Jeffrey K. Liker is Professor of Industrial and Operations Engineering at the University of Michigan and president of the Toyota Way Academy, a network of top-notch practitioners who consult, coach and teach in the Toyota Way. He authored the international best-seller, The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer, McGraw Hill, 2004 (26 languages, over 850,000 copies sold), and has coauthored six other books about Toyota: The Toyota Way Fieldbook, 2005, The Toyota Product Development System, Toyota Talent, 2007, and Toyota Culture: The Heart and Soul of the Toyota Way, 2008. His three newest books published in 2011 are: The Toyota Way to Continuous Improvement, Toyota Under Fire, and The Toyota Way to Lean Leadership: Achieving and Sustaining Excellence through Leadership Development. His newest book is Developing Lean Leaders at all Levels: A Practical Guide. His articles and books have won twelve Shingo Prizes for Research Excellence and The Toyota Way also won the 2005 Institute of Industrial Engineers Book of the Year Award and 2007 Sloan Industry Studies Book of the Year. In 2012 he was inducted into the Association of Manufacturing Excellence Hall of Fame and in 2016 inducted into the Shingo Academy.