Toyota Production System

Toyota Production System, An Integrated Approach to Just-in-Time, fourth edition, by Yasuhiro Monden, CRC Press

Now in its fourth edition, this manufacturing classic appeared in 2012.  Readers will find detailed chapters broken into segments that cover key TPS elements, such as one-piece production, kaizen, kanban, etc.  The chapter "Cultivating the Spontaneous Kaizen Mind" gets into the thinking of Taiichi Ohno when he developed and taught students about how to evaluate a production process and how to ask questions that would get to the key problems.  Indeed, this particular chapter may be currently the most talked-about area of production management because it deals with culture, change, engagement and leadership. 

Remember that although this book does include some sections that deal with IT - order entry systems, for example, in Chapter 6 -  because of the book's timeline, and its preponderant emphasis on uncovering and removing waste, along with employee development, these IT sections are somewhat dated.  Look elsewhere for insight as to how best to integrated up-to-date manufacturing IT systems, with TPS methods, although the book does include coverage of e-kanban solutions..

Nevertheless, for its in-depth review of the Toyota Production System, outside of the little green book, Monden is a great source with the new addition of the human side of lean.  Most production operations struggle with demand or forecast fluctuations, constant problems for which Toyota has worked out flexible solutions.  For quality management beyond inspection and rework, Toyota offers a very practical model.  All automotive producers deal with the threat of bankruptcy driven by simple quality failures like the Takata airbag recall; what late data can't supply, in principle engaged and observant employees will deliver.