Production System

Why do so many Lean implementations fail to deliver stable flow? Because they ignore the core secret behind Just-in-Time: Heijunka. In this concise, practical guide, Dr. Mohamed H. Soliman explains how production leveling — or Heijunka — helps organizations: Build predictable and stable production schedules Reduce overburden, bottlenecks, and downtime Align suppliers and internal processes for smoother flow Cut inventory without risking stockouts Unlock the full potential of Just-in-Time (JIT) systems Whether you're managing a factory floor or improving service operations, Heijunka is ...

At first, Taiichi Ohno, who helped create the Toyota Production System, didn't want to write it down because he was afraid people would only pay attention to the tools and theories. When he finally wrote it down, he described it as a house because a house can be considered as a system. If you remove any supports holding up the roof, the roof and everything connected to it will fall down. One of the students of Ohno said that Toyota made a mistake when they named it the Toyota Production System. Instead, Toyota should have named it the Thinking Production System because the main purpose was ...

Andon is a system that alerts people to problems before they happen, in order to make the process more efficient and prevent issues. In manufacturing, an andon is a system that tells managers, maintenance workers, and other employees about a problem with quality or the manufacturing process. But is this all that Andon being?Andon is a system that alerts people to problems before they happen, in order to make the process more efficient and prevent issues. In manufacturing, an andon is a system that tells managers, maintenance workers, and other employees about a problem with quality or the ...

Poka-yoke is a Japanese word that means "error-proofing". It involves using simple and cheap tools to help workers avoid making mistakes in their work. These devices prevent errors like using the wrong parts, forgetting to put in a part, or installing a part the wrong way. In simpler words, in Japanese, "poka" means making a mistake by accident, and "yoke" means stopping or avoiding the mistake. Have you ever wondered why Japanese cars are known for being reliable. Even cars that are 20 years old can still run well and keep up with the newest and top cars in the automobile industry. This is...

Want a workplace where people solve problems, improve continuously, and love what they do? That’s not luck — it’s Lean Culture. In this practical guide, Dr. Mohamed H. Soliman explores how Toyota creates a culture where improvement is everyone's job — not through pressure, but through daily behaviors, leadership, and purpose. You’ll learn: How to engage employees without micromanaging How to turn Lean from a “project” into a way of life How leaders build motivation, trust, and ownership The real role of managers in sustaining Lean habits Real examples of cultural ...

In recent years, financial professionals have been using outdated ideas and methods to judge how well companies are doing and give feedback to the bosses. This helps the executives and CEOs figure out what changes they need to make and make important choices. The boss wants assistance in locating the means to finance a new project. He wants to find areas where we can reduce costs in our products and services, as well as determine if changes made have led to making more money. The CEO wants assistance in understanding how the company has gotten better or worse and what the future will be ...

Pull production starts where most systems end — with the customer. Unlike traditional production where products are pushed into the market hoping someone will buy, pull production begins by listening to what is actually needed — how much, when, and where. In this clear and practical guide, Dr. Mohamed H. Soliman explains how pull systems work, how they reduce overproduction, and how they connect to Just-in-Time (JIT) as part of Toyota’s lean philosophy. You’ll learn: How downstream steps signal upstream steps for what is needed Why pull is the opposite of "make-to-stock" thinking ...

Takt is a German word that means the speed or rhythm of something. Takt time is a number that helps make sure that the pace of making pacemakers matches the pace of selling them. One of the most important things to consider in lean manufacturing is takt time. This is the rate at which customers want a certain group of products to be produced by one step in the manufacturing process. Takt time is a number that tells us how much time we have to make each item that the customer wants. Takt time is the time available for manufacturing divided by the number of orders. In the 1930s, the German ...

What if your machines could detect problems, stop themselves, and protect product quality — without constant supervision? That’s the power of Jidoka. In this concise, practical book, Dr. Mohamed H. Soliman explores how Jidoka, one of the two core pillars of the Toyota Production System, enables smarter operations by combining automation with human judgment. You’ll learn how Jidoka helps organizations: Build quality into every process Detect errors at the source and respond immediately Reduce waste and rework Free up operators to manage multiple machines (multiprocess handling) Create ...

How do you build reliable operations without killing innovation? The biggest challenge in implementing Standard Work is finding the right balance: Between giving employees clear, repeatable standards — and giving them space to think, improve, and grow. In this practical guide, Dr. Mohamed H. Soliman shows you how Toyota achieves that balance. You'll learn: Why most companies misunderstand Standard Work How to write effective standards that empower, not restrict Who should be involved in creating standards How Standard Work supports quality, cost, and delivery performance How it forms the ...

One of the biggest challenges in Lean is this question: “Where’s the financial benefit?” In many organizations, Lean feels like a set of good practices with unclear payoffs. But at Toyota, Lean principles and financial decision-making go hand in hand — not just for short-term savings, but for long-term strategic advantage. In this practical and thoughtful guide, Dr. Mohamed H. Soliman explores how to apply Lean Thinking to Cost-Benefit Analysis (CBA) — turning improvement efforts into clear, justifiable business value. You’ll learn: Why Lean must be connected to financial ...

Many kaizen programs aim to have a continuous flow, which means processes are constantly moving without interruptions. This is also the ultimate goal of lean production. A "cell" is a group of devices that perform tasks in a certain order, but it is not often to find a smooth and uninterrupted process, which is what makes a cell. In an ideal world, the product would flow smoothly from the beginning to the end, reaching the customer through all the stages of its production. But that would be too much to handle all at once. We need a place where we can focus. That place uses a system called a...

Toyota Motor Corporation made a system to make good products, save money, and make things faster by using less waste. TPS has two main parts, just-in-time and jidoka. It is often shown as a "house" image. To improve TPS and keep it running well, we use a process called PDCA or the scientific method. We do this by doing the same tasks over and over again and making small improvements called kaizen. TPS was created by Taiichi Ohno, who managed production at Toyota after World War II. Ohno began using TPS at Toyota in the 1950s and 1960s, starting with machining work. Then, he started using it...

By reducing waste and time spent waiting, the lean operational concepts and techniques aim to provide the greatest benefit for patients. It focuses a lot on staff being involved, making things better over time, and thinking about what the consumers want. All employees in the company, including doctors, staff, and managers, always work to find and remove any unnecessary things that don't help patients. They use lean concepts in healthcare to do this. To ensure that the staff on the assembly line always have the necessary parts and tools to finish their work, Toyota has established various ...

Genchi genbutsu is the Toyota way of thoroughly understanding a situation by personally observing and confirming information or data at the place where the situation is happening. For instance, when someone in charge is trying to figure out a problem, they will go to where the work is being done and watch how it's being done. They will also talk to the people doing the work to make sure the information is correct and to understand what's going on. They won't only trust information from a computer or from other people. This rule applies to both high-level leaders and lower-level supervisors....

Using lean metrics in non-manufacturing processes can help make things work better and make customers happier. The ideas of lean thinking, like finding what's valuable, getting rid of waste, and always trying to get better, work for all kinds of businesses. This book has lots of examples to show how lean principles can be used in non-manufacturing areas like healthcare, accounting, and maintenance.

Kaizen is not just about fixing processes — it's about growing people. Continuous improvement, or Kaizen, means making small, steady changes to make things flow better, work smoother, and serve customers more effectively. At its core, it’s not just a method — it’s a mindset. Yet many organizations misunderstand PDCA — treating it as a mechanical cycle for process improvement, while ignoring the development of the people behind the process. In this powerful and insightful book, Dr. Mohamed H. Soliman shows how true Kaizen and PDCA must go hand in hand: improving the system and ...

Conquer the NABCEP PV Design Specialist Exam (PVDS): Your Guide to Photovoltaic System Design Excellence is the ultimate resource for aspiring and experienced solar professionals aiming to master PV system design and achieve NABCEP certification. This comprehensive guide simplifies complex topics and provides practical knowledge to excel in solar design while ensuring safety, efficiency, and compliance with industry standards. The book begins with the fundamentals of photovoltaic systems, delving into component functions, solar resource assessment, and load analysis. It explores critical ...

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ACTION STATIONS! Enjoy Sci-Fi? Fantasy? Horror? Enjoy a Thrilling Suspense-Filled Fantasy Action Adventure set in a near future society with a solid dose of Horror in the mix. Now a COMPLETE SERIES of seven books: A Subtle Agency, A Traitor’s War, The Dragon’s Den, The Day Guard, The Crane War, The Key of Ahknaton, and The Metaframe Adept. Hunters and vampires are fighting a secret war for control of the fabric of reality. Whoever acquires mastery of the reality shifting powers of the Metaframe will become the new gods of the universe. "Imagine if you could change the rules of the game,...