Introduction By Michael Ballé
Phil Jenkinson Shares His Problem With Mike Woods
Mike Recommends That His Dad Help Phil
Meeting Bob Woods and Harry On Bob's Boat
Harry Breaks Down the Problem
They Visit Phil's Factory
Phil Explains the Product Lines
Phil Explains the Production and Assembly Lines
Bob Challenges Their Quality and Efficiency
Phil Describes Previous Improvement Efforts
Bob Recommends Adding a Second Line
After Lunch, Mike Asks Bob To Guide Phil
Bob Revisits the Factory, Meets Matt and Amy
The Group Seeks ''Gold'' In the Product Streams
Phil Shows Bob Packaging and Final Assembly
The Group Tours Testing and Mechanism Assembly
Bob Suggests Improvement Approaches
Phil and Amy Set Objectives For Improvement
Bob Helps Phil Look For Waste On the Assembly Line
The Value of Single-Piece Flow Is Discussed
Bob Contrasts Cost-Cutting With Cost-Saving
Later That Night, Phil Calls Mike
Mike Reflects On Belief
At the Factory, Production Chief Dave Opposes Stopwatches
At the Yacht Club, Bob Explains Takt Time
The Gang Learns To Calculate Takt Time
Muda, Muri, And Mura Are Introduced
''Zero Defects Accepted'' Established As Goal
Dinner, With Reflection On Red Bin Experiment
Bob Says To Enable Operators To Build In Quality
Back On the Boat, Timing of Cycles Is Discussed
Bob Explains Link Between Takt Time and Line-Balancing
From Push To Pull: All Supporting Kaizen
Amy Calls To Discuss Operator Resistance
Key To Operator Buy-In Is Proper System Design
Bob Says Supporting Workers Is Paramount
Yacht Club Gathering To Review Progress
Bob Depicts Standard Work Sequences
5S Is Introduced: Seiri, Seiton…
And Sieso, Seiketsu, And Shitsuke
A Yacht Club Talk On People
Bob Links Individual Involvement To Kaizen
Improvements Result In Reduced Work Content
The Gang Watches the Regatta
Boat Skippers Are Team Leaders
Team Leaders Anticipate Problems
Phil Updates Mike On His ''Mess''
A Field Trip To the Supermarket
Phil Bemoans His Long Final Assembly Runs
Bob Applies Supermarket Logic To Phil's Plant
