SHIGEO SHINGO SERIES

01  Zero Quality Control: Source Inspection and the Poka-Yoke System: - Summary A combination of source inspection and mistake-proofing devices is the only method to get you to zero defects. Shigeo Shingo shows you how this proven system for reducing errors turns out the highest quality products in the shortest period of time. Shingo provides 112 specific examples of poka-yoke development devices on the shop floor, most of them costing less than $100 to implement. He also discusses inspection systems, quality control circles, and the function of management with regard to inspection.

 

02  The Sayings of Shigeo Shingo: Key Strategies for Plant Improvement by Shigeo:- Here is a great introduction to the remarkable mind of Shigeo Shingo, indisputably one of the great forces in manufacturing. In this book Dr. Shingo describes his approach to manufacturing improvements, developed and refined over the course of a brilliant career. He called it the Scientific Thinking Mechanism (STM).                                                                                                                                                         
The Sayings of Shigeo Shingo leads you through the five stages of STM, with appropriate examples taken from notes Dr. Shingo collected during his consulting trips to American and Japanese plants. It shows how, in many cases, the most brilliant ideas are often so simple they're overlooked. Or they're dismissed because they seem ridiculous:
• A Japanese plant, after first rejecting the idea as "too silly," finds that unhulled rice is ideal for smoothing the rough surfaces on pressure-formed ebonite switches
• Granville-Phillips, in Boulder, Colorado, reduced defects to zero in one process after Dr. Shingo suggested illuminating circuit boards from below to reduce errors involved in the insertion of diodes and resistors
The Sayings of Shigeo Shingo is must reading for plant managers and engineers. It formalizes the powerful and creative way of thinking that Shingo himself used time and again to overcome problems that seemed virtually insurmountable.

 

03  A Revolution in Manufacturing: The SMED System :- Summary Written by the industrial engineer who developed SMED (single-minute exchange of die) for Toyota, A Revolution in Manufacturing provides a full overview of this powerful just in time production tool. It offers the most complete and detailed instructions available anywhere for transforming a manufacturing environment in ways that will speed up production and make small lot inventories feasible. The author delves into both the theory and practice of the SMED system, explaining fundamentals as well as techniques for applying SMED. The critically acclaimed text is supported with hundreds of illustrations and photographs, as well as twelve chapter-length case studies

 

04  A Study of the Toyota Production System: From an Industrial Engineering Viewpoint: - This is the "green book" that started it all -- the first book in English on JIT, written from the engineer's viewpoint. When Omark Industries bought 500 copies and studied it companywide, Omark became the American pioneer in JIT.
Here is Dr. Shingo's classic industrial engineering rationale for the priority of process-based over operational improvements in manufacturing. He explains the basic mechanisms of the Toyota production system, examines production as a functional network of processes and operations, and then discusses the mechanism necessary to make JIT possible in any manufacturing plant.
• Provides original source material on Just-ln-Time
• Demonstrates new ways to think about profit, inventory, waste, and productivity
• Explains the principles of leveling, standard work procedures, multi-machine handling, supplier relations, and much moreIf you are a serious student of manufacturing, you will benefit greatly from reading this primary resource on the powerful fundamentals of JIT.

 

05  Non-Stock Production: The Shingo System for continuous improvement:-Summary Shingo, whose work at Toyota provided the foundation for JIT, teaches how to implement non-stock production in your JIT manufacturing operations. The culmination of his extensive writings on efficient production management and continuous improvement, this book is an essential companion volume to his other landmark books on key elements of JIT, including SMED and poka-yoke. It covers-- Fundamental flaws in European and American production philosophies. Basic concepts for improving production systems. The "scientific thinking mechanism" -- a new approach to improvement. Implementing a production method in an age of authorized stock production. Development of production functions in the age of non-stock production. Significance of the different production systems.

 

06  Understanding A3 Thinking: A critical component of Toyota’s PDCA Management System : - Winner of a 2009 Shingo Research and Professional Publication Prize. Notably flexible and brief, the A3 report has proven to be a key tool In Toyota’s successful move toward organizational efficiency, effectiveness, and improvement, especially within its engineering and R&D organizations. The power of the A3 report, however, derives not from the report itself, but rather from the development of the culture and mindset required for the implementation of the A3 system. In other words, A3 reports are not just an end product but are evidence of a powerful set of dynamics that is referred to as A3 Thinking.
In Understanding A3 Thinking, the authors first show that the A3 report is an effective tool when it is implemented in conjunction with a PDCA-based management philosophy. Toyota views A3 Reports as just one piece in their PDCA management approach. Second, the authors show that the process leading to the development and management of A3 reports is at least as important as the reports themselves, because of the deep learning and professional development that occurs in the process. And finally, the authors provide a number of examples as well as some very practical advice on how to write and review A3 reports.