The Lean Toolbox: The Essential Guide to Lean Transformation, John Bicheno, Matthias Holweg,

Production and Inventory Control, Systems and Industrial Engineering (PICSIE) Books, 2009,
0954124456, 9780954124458, 290 pages. 'The Lean Toolbox 4th Edition, the Essential Guide to
Lean Transformation' is written for practitioners and for students, and is the extensively revised
version of the best selling 'The New Lean Toolbox'. The book has sections on The Philosophy of
Lean, Value and Waste, Transformation Frameworks, Deployment, Preparing for Flow, Mapping,
Layout and Cell Design, Scheduling, TOC, Quality, Improvement, Managing Change, Sustainability,
New Product Development, The Lean Supply Chain, and Accounting and Measurement..
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'The Lean Toolbox 4th Edition, the Essential Guide to Lean Transformation' is written for
practitioners and for students, and is the extensively revised version of the best selling 'The New
Lean Toolbox'. The book has sections on The Philosophy of Lean, Value and Waste,
Transformation Frameworks, Deployment, Preparing for Flow, Mapping, Layout and Cell Design,
Scheduling, TOC, Quality, Improvement, Managing Change, Sustainability, New Product
Development, The Lean Supply Chain, and Accounting and Measurement.
John has graduate degrees in Engineering, Systems and Management, and is CFPIM certified by
APICS. Following 10 years in operations management and engineering, he started his Lean journey
while at the University of the Witwatersrand in the early 1980’s, and continues to learn. He
has been a mentor, trainer and consultant to scores of companies, and is on the board of AME UK.
--This text refers to an out of print or unavailable edition of this title.
The New Lean Toolbox is a great compilation and summary of all the lean approaches being
deployed today. Bicheno ties together all these approaches in a framework that elevates the readers
understanding of how lean works as an interlocking system of techniques not as isolated tools. It is
a excellent companion and guide to the world of lean and it will lead to rich sources of deeper
learning on its vast subject matter. It is a veritable lean in short hand book that is the best possible
thesaurus /codex for any lean practitioner or novice alike.
The bulk of the book consists of a list of tools based around the author's framework, targeted at
experienced Lean practitioners. The author explains that he does not expect all the tools to be used
on all engagements; rather it is up to the reader to use their experience to select the best tools for a
particular problem. Bicheno also stresses that the Lean process is continuous, iterative process. His
framework consists of following sections:
The section involving Strategy is especially interesting as the author is clearly familiar with
executive-level business theories that define and improve value. He advocates Kano analysis as the
most powerful technique in for developing products; he has a good section on Scenarios (although
his failure to extend this to mention assumption-based planning is little surprising); he outlines how
Lean techniques are complementary with Kaplan and Norton's Balanced Scorecard and credits Jim
Collins as succinctly defining the primary characteristics of people management.
One of the key parts of Lean is to determine which parts of the business add value and which parts
do not - the value-stream. In the section dealing with this, Bicheno gives detailed advice on the tools
to help with this; here there is overlap with business process modelling. In the Costing section, he
makes a plea for simplified accounting practises, naming conventional activity-based accounting as
too bureaucratic.
This is a hugely comprehensive book summarising the latest thinking in Lean. It is biased towards
manufacturing - not surprising, as Lean practitioners have only recently turned their attention to the
service sector. As so much material is packed in, some of the text is succinct - to the point of
terseness at times; no matter, every experienced practitioner will want a copy close to hand. Read
more ›
As an example, The New Lean Toolbox briefly describes six different types of Kanban, plus the
related Ford System,CONWIP and POLCA in six concise pages. It mentions two more types. Rules
of Kanban and calculating the number of Kanban cards is included, including calculations for special
circumstances.
The Lean Tool Box is an excellent book for anyone working in the continuous improvement field.
What I like best about it was that it wasn't just focused on Lean tools and techniques, but also
included Six Sigma and the Theory of Constraints. I have always used an integrated Theory of
Constraints, Lean and Six Sigma methodology and this book just reinforces why this integration
works so well.
The Lean Toolbox 4th Edition contains sections on Philisophy, Value and Waste, Lean
Trasformation Frameworks, strategy, Planning, Deployment, Preparing for Flow, Mapping,
Assessments and Analysis, Layout and Cell Design, Scheduling, Theory of Constraints and Factory
Physics, Quality, Improvement, Managing Change, Sustainability - making change stick, New
Product Development and Introduction, Creating the Lean Supply Chain, Accounting and
Measurement, Lean - How it all came about, Further Resources.
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