Look Forward Beyond Lean and Six SIGMA: A Self-Perpetuating Enterprise Improvement Method

A very impressing book! For many years there has been a short- sighted, misapplication of "flavor of the month Quality Programs". They have all been tools of our trade but not the answer to all quality problems individually. Organizations have abandoned them one by one because of disappointing results. Every time a new program was implemented from scratch, there were equally disappointing results. Mr. Dirgo addresses this very well as he discusses the integration of the tools from "Zero Defects" through "Six Sigma" to support Continual Improvement. He implies that it must be a way of life, not just a program. This enlightening book has addressed the problem integration of quality concepts to make improvement self-perpetuating. Mr. Dirgo has given examples and case studies from personal experiences that allow the reader to see the results in a very practical way. This book effectively promotes "out of the box" thinking with a look forward.

The first chapters provide an easy to follow overview of Lean. The origins and evolution of Lean are nicely summarized. Numerous success stories from Automotive, A & D, and High Tech explain how companies such as Toyota, Dell, GE, HP, and others have been successful. Later chapters tell the Lean Six Sigma Story of the author's company, Aircraft Braking Systems Corporation, ABSC. We read how ABSC addressed production quality by understanding the importance of the pre-production design and launch process. Like many companies ABSC was managed in 'Silos' with various departments such as Engineering, Purchasing, and Manufacturing each working to their own performance metrics to the detriment of corporate performance. ABSC recognized this and implemented cross functional launch teams with members from the various departments with a common set of performance metrics. This concept has been applied in other industries and advocated by 'Outside Experts' but ABSC figured this out on their own, took ownership, and wrote their own success story.

Not just theory. Mr. Dirgo reflects the environment in which he lives and works. His is a purview of the methods, practices and perspectives that are the functional underpinnings of an extremely successful AS 9001: 2000 (Aerospace) registered Quality System that is harmonized with most other modern quality initiatives of Lean, 6 Sigma, etc. The writing is succinct and allows the reader to understand the "Look Forward" continuous approach that really makes it all come together without mystery, magic or esoteric hocus-pocus.

If you are looking for a book that demystifies the statistical tools associated with lean manufacturing and continuous improvement, this one is for you. Dirgo uses everyday language to explain the role of top management, the use of teams and the selection and application of the correct analytical tools to drive cost down while improving quality. The case studies are especially useful because they demonstrate the processes involved, and show that the end is not attained simply when the original objective is achieved. Rather, one door closes and another opens.

Look Forward® Beyond Lean and Six Sigma By Robert Dirgo Hardcover, 6 x 9, 240 Pages ISBN: 1-932159-46-0 Publishing August 2005 Institute of Aerospace Excellence About the Item: This book introduces the Look Forward approach to continuous improvement (CI). Look Forward is a management approach to CI that fosters an environment that infuses CI into the very fabric of the organization. As a result, improvement is not an initiative or a project but rather a natural occurring event that is anticipated, expected and prevalent. Look Forward is not a substitute for Six Sigma, Lean or Theory of Constraints (TOC), but rather is a necessary complement to each of these in order to assure self-perpetuating improvement that is ingrained in the corporate culture. It, in turn, needs Six Sigma, Lean and TOC methodologies to be the fuel for the improvement engine that drives the company forward. Any business serious about improvement is going to consider Six Sigma, Lean and TOC in the overall scope of their operations and the unique benefits they bring to the table. This book shows that for unbeatable sustained improvement, Six Sigma, Lean and TOC need to be intertwined with the Look Forward methodology. Key Features: Helps you build a foundation within your business that will support a robust improvement management method Includes an overview of Lean, Six Sigma and Theory of Constraints and how they can be used together by management for constant improvement Provides the mechanics of the day-to-day execution of a synergistic continuous improvement management method Features several case study examples that you can use to relate to your company Promotes a corporate culture that will foster on-going, perpetual improvement throughout the organization without the necessity of intervention About the Author(s): Robert Dirgo has over twenty-five years experience working in the steel and aerospace industries. Mr. Dirgo is currently Manager of Process Quality Assurance at Aircraft Braking Systems Corporation (ABSC). As one of the overseers of the continuous improvement effort, he was also one of the original management members that developed the Look Forward management method in 1996. He holds a Bachelor's degree in Mechanical Engineering, a Master's degree in Statistics and has been certified by the American Society of Quality as a Certified Six Sigma Black Belt, a Certified Quality Engineer and a Certified Quality Auditor. Table of Contents: Look Forward - How to Manage the Business of Improvement Your Industry Standard - A Framework for Look Forward Improvement Six Sigma Lean Manufacturing Theory of Constraints The Challenge of Maintaining Continuous Improvement Look Forward - The ABSC Way Look Forward Case Studies Enterprise Level Improvement Initiatives Conclusion Bibliography Glossary Appendix Index