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9781032113913

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Eric and Matt have thought about why most kaizen is really rework for poorly designed processes. They have developed a way to align all parts of an organization to eliminate waste of all sorts in production processes before the start of production. I'm delighted with their important contribution to Lean Thinking that goes far beyond 3P and other methods of process development. -- James P. Womack, PhD, Co-founder of the global Lean movement; Co-Author, Lean Thinking and The Machine That Changed The World; Founder, Lean Enterprise Institute Making things is important. Making things well with high quality, on time and low cost with improvements everyday leads to success and prosperity. The Power of Process both outlines the end goals and provides a realistic story of the path for getting to extraordinary goals. The book is well worth an investment of time and energy. -- Don Runkle, Senior Multi-Industry Executive; Former CTO & Board Member, Delphi Automotive Systems; Former Engineering VP, General Motors With The Power of Process, Matt Zayko and Eric Ethington give us something unique in the world of books about continuous improvement, management, and work design, which typically focus on either the product or the people creating it: this book shares a practical approach for engaging people in developing great processes. Anyone involved in designing or managing work should keep this book handy for quick reference on their physical or digital desktop. -- John Shook, Chairman Lean Global Network The timing for this book could not be better. Many organizations are so very frustrated with their lack of CI progress. This framework is certain to help them to close the gap and adds context to demystifying lean transformation. And I love the presentation of learning through doing using case studies to cement the approach. -- Crystal Davis, Founder & CEO, The Lean Coach Inc.; Experienced Operations and Engineering Leader at Fortune 50 Companies Finally, a book that lays out how to apply lean concepts to the process development phase through launch. The authors have done an excellent job of showing the benefits of engaging a cross functional team early on in the process so that touzen (rework) does not take place after launch. I only wish this book would have been in print earlier in my career. -- Mary O'Neill, Senior Vice President Lean Manufacturing, Gates Industrial Corp The Power of Process is a remarkable guide and a must-read primer for anyone considering embarking on their own process design transformation. Through this self-reflective story, we are challenged by the reality in which we live today and inspired to drastically change our future -- NOW. -- Mari Cummins, Retired Vice-President of Operations Excellence, Cardinal Health; Coach for the Master of Business of Operational Excellence at Fisher College of Business at the Ohio State University

Eric and Matt have thought about why most kaizen is really rework for poorly designed processes. They have developed a way to align all parts of an organization to eliminate waste of all sorts in production processes before the start of production. I'm delighted with their important contribution to Lean Thinking that goes far beyond 3P and other methods of process development. -- James P. Womack, PhD, Co-founder of the global Lean movement; Co-Author, Lean Thinking and The Machine That Changed The World; Founder, Lean Enterprise Institute Making things is important. Making things well with high quality, on time and low cost with improvements everyday leads to success and prosperity. The Power of Process both outlines the end goals and provides a realistic story of the path for getting to extraordinary goals. The book is well worth an investment of time and energy. -- Don Runkle, Senior Multi-Industry Executive; Former CTO & Board Member, Delphi Automotive Systems; Former Engineering VP, General Motors With The Power of Process, Matt Zayko and Eric Ethington give us something unique in the world of books about continuous improvement, management, and work design, which typically focus on either the product or the people creating it: this book shares a practical approach for engaging people in developing great processes. Anyone involved in designing or managing work should keep this book handy for quick reference on their physical or digital desktop. -- John Shook, Chairman Lean Global Network The timing for this book could not be better. Many organizations are so very frustrated with their lack of CI progress. This framework is certain to help them to close the gap and adds context to demystifying lean transformation. And I love the presentation of learning through doing using case studies to cement the approach. -- Crystal Davis, Founder & CEO, The Lean Coach Inc.; Experienced Operations and Engineering Leader at Fortune 50 Companies Finally, a book that lays out how to apply lean concepts to the process development phase through launch. The authors have done an excellent job of showing the benefits of engaging a cross functional team early on in the process so that touzen (rework) does not take place after launch. I only wish this book would have been in print earlier in my career. -- Mary O'Neill, Senior Vice President Lean Manufacturing, Gates Industrial Corp The Power of Process is a remarkable guide and a must-read primer for anyone considering embarking on their own process design transformation. Through this self-reflective story, we are challenged by the reality in which we live today and inspired to drastically change our future -- NOW. -- Mari Cummins, Retired Vice-President of Operations Excellence, Cardinal Health; Coach for the Master of Business of Operational Excellence at Fisher College of Business at the Ohio State University

Author Information

Matt Zayko has more than 25 years of experience in leading lean enterprise improvements in numerous industries by helping them transform product development, engineering, manufacturing, service processes, and operating systems. Matt worked in a variety of staff- and management-level roles under the guidance of former Toyota mentors for Chrysler / University of Michigan, Gelman Sciences, Delphi, and Pall (now part of Danaher) before starting his own consultancy and affiliating with the Lean Enterprise Institute (LEI). Matt has authored numerous works based on successful transformation, including articles that have been published in “Journal of Quality Engineering”, “IIE Solutions”, “Journal of Cost Management”, a chapter in the 1998 Shingo-Prize winning book “Becoming Lean”, and white papers for the Lean Enterprise Institute. Matt is a frequent presenter at conferences related to lean transformation and a long-time faculty member of LEI (www.lean.org), working closely with smaller, entrepreneurial-minded organizations, as well as larger, global companies. Matt received his M.S. in Industrial & Operations Engineering from the University of Michigan at Ann Arbor. Eric Ethington is passionate about improvement, with over 35 years of experience feeding that passion. Starting as a fabrication area industrial engineer at General Motors’ AC Spark Plug division, making today better than yesterday has always been part of Eric’s routine. For 22 years Eric had formative experiences at Delco Electronics and Delphi, making him comfortable working with front-line operators within the plants up to senior executives at the company headquarters alike. Eric’s final years at Delphi had him leading the company’s corporate lean team, and developing and implementing processes specifically targeted at improving new product launch performance. Eric then spent the next five years in an executive position at Textron, supporting lean and six-sigma activities across several diverse businesses and industries. It was during this period that Eric earned his six-sigma black belt in design. Since 2009, Eric has continued learning and advancing both the science and art behind lean throughout the enterprise, working in diverse industries such as aerospace, healthcare, services, manufacturing and logistics. Eric holds a Bachelor of Science degree in industrial Engineering from Kettering University (formerly General Motors Institute) and an MBA in Operations from the University of Michigan, Flint campus. He supports the Lean Enterprise Institute in support of their Lean Product & Process Development initiative, and he serves on the Board of Directors at Goodwill Industries of Mid-Michigan.

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