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Songs (108)
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Introduction By Michael Ballé
Phil Jenkinson Shares His Problem With Mike Woods
Mike Recommends That His Dad Help Phil
Meeting Bob Woods and Harry On Bob's Boat
Harry Breaks Down the Problem
They Visit Phil's Factory
Phil Explains the Product Lines
Phil Explains the Production and Assembly Lines
Bob Challenges Their Quality and Efficiency
Phil Describes Previous Improvement Efforts
Bob Recommends Adding a Second Line
After Lunch, Mike Asks Bob To Guide Phil
Bob Revisits the Factory, Meets Matt and Amy
The Group Seeks ''Gold'' In the Product Streams
Phil Shows Bob Packaging and Final Assembly
The Group Tours Testing and Mechanism Assembly
Bob Suggests Improvement Approaches
Phil and Amy Set Objectives For Improvement
Bob Helps Phil Look For Waste On the Assembly Line
The Value of Single-Piece Flow Is Discussed
Bob Contrasts Cost-Cutting With Cost-Saving
Later That Night, Phil Calls Mike
Mike Reflects On Belief
At the Factory, Production Chief Dave Opposes Stopwatches
At the Yacht Club, Bob Explains Takt Time
The Gang Learns To Calculate Takt Time
Muda, Muri, And Mura Are Introduced
''Zero Defects Accepted'' Established As Goal
Dinner, With Reflection On Red Bin Experiment
Bob Says To Enable Operators To Build In Quality
Back On the Boat, Timing of Cycles Is Discussed
Bob Explains Link Between Takt Time and Line-Balancing
From Push To Pull: All Supporting Kaizen
Amy Calls To Discuss Operator Resistance
Key To Operator Buy-In Is Proper System Design
Bob Says Supporting Workers Is Paramount
Yacht Club Gathering To Review Progress
Bob Depicts Standard Work Sequences
5S Is Introduced: Seiri, Seiton…
And Sieso, Seiketsu, And Shitsuke
A Yacht Club Talk On People
Bob Links Individual Involvement To Kaizen
Improvements Result In Reduced Work Content
The Gang Watches the Regatta
Boat Skippers Are Team Leaders
Team Leaders Anticipate Problems
Phil Updates Mike On His ''Mess''
A Field Trip To the Supermarket
Phil Bemoans His Long Final Assembly Runs
Bob Applies Supermarket Logic To Phil's Plant
Bob Explains Importance of Leveling
Leveling Reduces Inventory
Logistics For Final Assembly Discussed
Phil Explains Final Assembly Changes
A Dinner Discussion With Steve MacAllister
MacAllister Illustrates the Nuances of Batch Size
The Famous ''Lake and Rocks'' Analogy
Phil and Amy Discuss New Product Lines
Bob Advises On Changeover Challenges
Create Supermarkets As Countermeasure
Bob Suggests Improvements To Truck Prep Area
A Lean Implementation Sequence Is Outlined
They Tour the Redesigned Factory Floor
Phil and Amy Show Off the Mechanism Supermarket
Kanban Shown To Support Pull
Dave Points To Supermarket Problems
Withdrawal Kanban and Heijunka Box Are Explained
Bob Relates Conveyor Sequence To Picking Order
Bob and Harry Return To the Factory
Dave Complains About Missing Parts
Kevin Morgan Reveals His MRP Ordering Strategy
The Crew Regroups After a Heated Fight
Bob Reaffirms the Importance of the Gemba
Kanban Is a Kaizen Tool (Not Vice Versa)
They All Visit the Presses
Phil Explains How the Presses Run
Amy Learns Flow For the Presses
Bob Outlines SMED and Cell Flow
''What Do You See''
TPM and 5S In the Job Shop
The Five Whys Are Pursued
Bob Links All To a Gemba Attitude
Amy Calls Mike With an Idea
The Press Operators Pitch In
A Shop Floor Confrontation
Mike Reflects On Transformation
Bob Quits, Phil Panics, Bob Reconsiders
Bob Shares His Lean Principles
Mike and Amy Have Lunch, Talk Shop
Bob advises On MRP-Free Scheduling
Buffer Stock and Safety Stock Are Tackled
Progress Update At the Yacht Club
Bob Introduces Value-Stream Mapping
Information Flow Affects Inventory
Use Heijunka Thinking For Forecasting
Phil and Mike Talk On the Docks
Amy Quits, Sparking Leadership Discussion
Tanaka-San Visits the Factory
That Evening Bob Explains Tanaka's Behavior
Bob Explains the Importance of Jidoka
Poka-Yoke and Continuous Improvement
Bob Elaborates On Kaizen Attitude
Standardized Work As the Basis For Kaizen
Mike Reflects On the Nature of Improvement
Mike and Amy Discuss Her New Job
''Never, Never, Never Give Up!''
Copyright
An Extended Q&a With Michael Ballé and the Gold Mine Editor Tom Ehrenfeld
Listen on Apple Music
Provided courtesy of Apple Music.