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 adventure with Toyota’s grasp academics and with businesses in the course of nice switch, Andy & Me is a enterprise novel set in a failing New Jersey car plant concentrating on the tribulations of Tom Pappas, the plant supervisor. The events, characters and plant politics will ring real with many readers.

In a funky, readable kind, Andy & Me follows Tom's dating with Andy Saito, a reclusive, retired Toyota guru whom Tom persuades to aid shop his plant in the course of the instructing of the mythical Toyota construction method (TPS).

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

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I’d say it happens once a week,” he said. ” The sky was as bleak as our prospects. ” To build a Desperado you have to stamp it, weld it, paint it, and stuff it. Rail cars bring coils of sheet metal to the Stamping or Press shop. Blanking machines cut it into rectangular blanks, which are fed into our presses. These bring matching upper and lower dies together to create doors, hoods, floor panels, and other parts. © 2011 by Taylor & Francis Group, LLC 31 32 • Andy & Me Dies can weigh 30,000 pounds.

Then we remove the doors, which © 2011 by Taylor & Francis Group, LLC 40 • Andy & Me we reinstall after we’ve added window glass, hardware, and trim. Next come the struts, instrument panel, windshield, and back window. Then we install seats, bumpers, steering column, headliner, and tires. We stopped in front of the headlight install process at the end of Trim line 1. You could barely see behind all the parts. ” “We’ve had quite a few part-outs here lately,” Jeff replied. ” Jeff seemed uncomfortable.

Konnichiwa, Mr. ” Hey now! “But you must agree to some conditions. You must make safety priority number one. Ergonomics is bad. You must develop an ergonomic strategy. Also, there are too many pinch points and blind corners. “Next, you must clean and paint factory. Work areas are in bad condition. Garbage is everywhere! I will make a list. You fix. One last thing, when I give assignments, you must do. Discuss yes. Argue no. ” I agreed. The next day Andy and Bill came into the plant and we spent a couple of hours confirming the details.

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