Andy & me : crisis and transformation on the lean journey by Pascal Dennis

By Pascal Dennis

2006 SHINGO PRIZE for EXCELLENCE in production RESEARCH

Based at the author's own event with Toyota’s grasp lecturers and with businesses in the middle of nice swap, Andy & Me is a company novel set in a failing New Jersey vehicle plant targeting the tribulations of Tom Pappas, the plant supervisor. The events, characters and plant politics will ring precise with many readers.

In a funky, readable kind, Andy & Me follows Tom's courting with Andy Saito, a reclusive, retired Toyota guru whom Tom persuades to aid keep his plant during the educating of the mythical Toyota construction approach (TPS).

On this trip, the reader learns that TPS is greater than only a number of instruments; it involves a brand new state of mind and behaving. notwithstanding Tom reveals luck ― either in his plant and in his own existence ― he learns from Andy that profitable development is "endless and eternal."

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Extra resources for Andy & me : crisis and transformation on the lean journey

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We will print out a large copy of this paper and post it on tripod next to metal repair booth. Every hour the supervisor will record results. At shift-end, the team will reflect. ” We spent several minutes looking it over. “Mr. Saito,” Fred asked, “we already record some of this data in our computer system. ” “For visual management, Fred-san. The computer is a good tool, but only one person can see the screen. Every team member must be able to see the current condition. ” None of us had heard of it.

What is output each hour? What is quality and lead time? ” “I like that approach, sensei. But I’m concerned. If our numbers look bad, Jed Morgan may try to shut us down. ” “I will speak with Bill-san and Rachel-san,” said Andy. All this was in the back of my mind as Sylvain demonstrated the wonders of Virtual Manufacturer. Andy watched politely. When it was over, he praised Sylvain for the “good software” and summarized his observations. As in Stamping, he had identified our weak spots. Sylvain waited quietly for Andy to finish.

A breakdown anywhere along the line can stop the flow. To protect ourselves, we put in buffers. There are piles of parts at each workstation; our parts warehouse is a labyrinth. Our plant is also a chessboard. Our opponent is entropy— decay, chaos, Death, if you will. Entropy always wins in the end. This old plant will be gone some day, as will all of us who work here. But if you’re good, you can play him to a standstill. You can even push him back for a while. © 2011 by Taylor & Francis Group, LLC 30 • Andy & Me To build a great car you also need heart.

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