Liquid Lean: Developing Lean Culture in the Process Industries

While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author’s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of the problem is resistance to transformational change, a barrier that can only be overcome with effective leadership and results-oriented planning that engages rather than excludes all stakeholders.

Winner of a 2012 Shingo Prize!

Written by Raymond Floyd, an unparalleled leader of Lean transformations,Liquid Lean: Developing Lean Culture in the Process Industries provides potential process industry change agents with the no-nonsense guide needed to eliminate waste and achieve sustainable optimal efficiency. Presenting lessons in lean as they apply within the liquid industries, the book focuses on developing the four measures of Lean as defined by the Shingo Award:

1. Business Results
2. Consistent Lean Enterprise Culture
3. Continuous Process Improvement
4. Cultural Enablers

Illustrated with his own success stories, Floyd describes business results, Lean enterprise thinking, and policy deployment in process industry terms. He offers detailed theory, practice, and examples of continuous process improvement, and describes the leadership and defines the ethics needed to evolve and sustain Lean transformation. Floyd lays out the specific steps needed during the first six months of transformation and the benchmarks to be achieved during the first two years of implementation. All companies can benefit from Lean; this book makes sure that those who want it, know how.

• Lean for the Process Industries: Dealing with Complexity
• Value Stream Mapping for the Process Industries: Creating a Roadmap for Lean Transformation
• Learning to See: Value Stream Mapping to Add Value and Eliminate MUDA
• The Product Wheel Handbook: Creating Balanced Flow in High-Mix Process Operations
• A Culture of Rapid Improvement: Creating and Sustaining an Engaged Workforce
• The Goal: A Process of Ongoing Improvement
• Lean Thinking: Banish Waste and Create Wealth in Your Corporation, Revised and Updated
• Managing to Learn: Using the A3 Management Process to Solve Problems, Gain Agreement, Mentor and Lead
• The First 90 Days: Proven Strategies for Getting Up to Speed Faster and Smarter, Updated and Expanded
• Extreme Operational Excellence: Applying the US Nuclear Submarine Culture to Your Organization