Quantum Lean

“This is a very complete treatment of lean methods and belongs on every lean practitioner bookshelf. In particular, the focus on lead time reduction is especially relevant, as opposed to the traditional focus on waste reduction which can quickly trap an organization in a cost reduction strategy that can destroy it.”

—Carol Ptak, Demand Driven Institute

“Quantum Lean is a must read for anyone looking to improve manufacturing capabilities at all levels of management. Thank you, Sean and Michael, for putting pencil to paper and sharing this valuable information.”

—David Stevens, North America Manufacturing Manager, Fortune Global 500 Company

“Quantum Lean lays out a powerful argument for how a lean implementation should be approached and how a lean culture can be sustained in any working environment. This is a winner and a must read for anyone interested in taking their company to the next level.”

—Sam Kelton, VP/GM, Triangle Pump Components, Inc.

“This book hammers home the point that all lean practices must be implemented with the best interest of owners, managers, workers, and customers in mind. In other words, adaptation to the workplace so everyone gains from changes is absolutely necessary for lasting, long-term improvements.”

—William Kolarik, Professor and Bentley Chair of Industrial Engineering (Retired), Oklahoma State University

This unique guide details a revolutionary approach to lean systems. Whereas traditional lean techniques suffer from less-than-inspiring results, Quantum Lean (QL) rethinks this subject and provides an overdue remedy. The key to this breakthrough is that QL approaches lean systems from an entirely different perspective than conventional methods. Instead of focusing on resource utilization, QL centers on achieving efficiency from the standpoint of a company’s product. The benefits from this simple departure are vast and wide-ranging. In terms of speed, effectiveness, and sustainability, QL offers a superior process for transforming an enterprise and gives practitioners a way to avoid the shortcomings that are commonplace in conventional lean.

In addition to being geared toward lean practitioners and consultants, the book is also useful for the C-suite, managers, supervisors, technical staff, and rank-and-file employees. It is intended for those who work in all economic sectors, including services, manufacturing, and government.

Sean Fields, P.E., LSSBB, MSIE, has over 30 years of experience in a wide variety of industries, including oil field equipment manufacturing, food processing, and job shops. As a seasoned industry professional, he has worked in all phases of business, including the shop floor, quality, safety, and engineering. Over the years, he found himself in a great deal of situations where he was expected to implement lean approaches in environments where conventional lean methods were impractical. However, by returning to the fundamentals pioneered by Henry Ford, Fields found that lean could be sustainably applied in practically any setting. With successful implementations in the most challenging environments, he now wants to share his experiences, ideas, and approaches for businesses to reach the next level of success.

In addition to being an active lean practitioner, Sean is a network member of the non-profit organization BeehiveFund, that assists companies with production scheduling, inventory control, and developing quality management systems (ISO 9000, AS9100, and API Q1). He is also a columnist for the Lubbock Avalanche Journal, a licensed professional engineer in the state of Texas, a certified Six Sigma Master Black Belt, and a certified QMS auditor.

Michael Sanders, Ph.D., LSSBB, MBA, is the co-founder of BeehiveFund, a non-profit organization dedicated to assisting industry. Michael has worked in every phase of the supply chain at a wide variety of companies, including serving as CEO and president of food, energy, distribution, and high-tech firms. Along this journey, he and Sean have collaborated extensively to refine the Quantum Lean framework and successfully deliver their lean methods to numerous companies.

In addition to his work as a seasoned executive and practitioner, Dr. Sanders is sought after for his expertise in negotiation, organizational psychology, Six Sigma, quality systems, and regulatory compliance. He has delivered speeches worldwide on topics that include global supply chain optimization, lean and beyond lean production systems, quality and regulatory systems, optimal and effective leadership, product-centered sustainable growth, organizational culture transition, and emerging technologies. Michael has a Ph.D. in Industrial Engineering and an MBA from Texas Tech University. In addition, he holds a certification as a Six Sigma Master Black Belt.

Chapter 1: Defining Quantum Lean, Part 1

Chapter 2: Defining Quantum Lean, Part 2

Chapter 3: Defining Quantum Lean, Part 3

Chapter 4: Product Path Diagram

Chapter 5: Quantum Lean Tools

Chapter 6: Applying Product Path Diagramming

Chapter 7: A Final Review of QL

Chapter 8: Quantum Lean vs. Other Approaches

Chapter 9: Inventory

Chapter 10: Shop Floor Control/Logistics/Scheduling

Chapter 11: 5S (Workplace Organization)

Chapter 12: Kanban

Chapter 13: Quick Changeover

Chapter 14: Quantum Lean Maintenance (QLM)

Chapter 15: Visual/Audible/Tactile Workplace

Chapter 16: Standard Work

Chapter 17: Work Balancing

Chapter 18: Cellular Production

Chapter 19: Quality@Source

Chapter 20: Lean Implementations: Improving the Odds

Chapter 21: Potemkin Lean

Appendix A: Inventory Primer

Appendix B: Glossary

Appendix C: Sources

Index