Made-to-Order Lean: Excelling in a High-Mix, Low-Volume Environment

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Taylor & Francis, Aug 15, 2007 - Business & Economics - 224 pages
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Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs.

About the author:

Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS.

He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales.

Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email:

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Managing Visually AlklxioI
Management Auditing Standardized Work for Managers
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About the author (2007)

Greg Lane has owned and successfully transformed his own company, along with supporting others in leadership improvements in 32 countries, with diverse types of organizations. He has effectively led change while holding management and executive positions at General Motors and Delphi Automotive. His 25 years of worldwide experience was strongly influenced while working for Toyota in the late 1980s, when he was one of a handful selected to be developed as a Toyota Key Person, through a year of specialized training in Japan. This included working with Toyota's top trainers, and then returning to train others within Toyota at their U.S. sites. Greg learned early on that it's not technical tools and methodologies that drive the break-throughs; instead, it's cascading leadership throughout the organization and focusing leaders on a clearly communicated and deployed strategy. Today, Greg is internationally recognized as a coach in creating organizational change, and has been invited to speak on five continents about these successes. Also a recognized author, he has written these additional books and published in leadership and technical medias: Made to Order Lean-Excelling in a High-Mix, Low-Volume Environment (Productivity Press, New York: 2007) Mr. Lean Buys & Transforms a Manufacturing Company-The True Story of Profitably Growing an Organization with Lean Principals (CRC Press, New York: 2010) Chapter 9 of Toyota by Toyota-Reflections from the Inside Leaders on the Techniques That Revolutionized the Industry (CRC Press, New York: 2012) Greg is a facility member of the Lean Institutes in the USA and Spain, as well as lecturer of post-graduate lean studies at the University Polytechnic Barcelona. He holds a B.S. in mechanical engineering from the University of Wisconsin as well as an MBA degree with distinction from California State University. He speaks English, Spanish and German. Greg and his associates provide cost effective support for improvements and transformations. He can be contacted at or more information can be found at: http: //

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