Made To Order Lean
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Made To Order Lean
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Author : Greg Lane
language : en
Publisher: CRC Press
Release Date : 2020-03-09
Made To Order Lean written by Greg Lane and has been published by CRC Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2020-03-09 with Business & Economics categories.
Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs. About the author: Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS. He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales. Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: glane@lowvolumelean.com
Speed To Market
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Author : Vincent Bozzone
language : en
Publisher: Amacom Books
Release Date : 2002
Speed To Market written by Vincent Bozzone and has been published by Amacom Books this book supported file pdf, txt, epub, kindle and other format this book has been release on 2002 with Business & Economics categories.
"Lean manufacturing is the single most effective way to increase sales, cut costs, improve margins, and secure the future of a business. The problem is that the principles and philosophies of lean manufacturing are geared strictly to mass production operations--and can be ineffective, even detrimental, for smaller job shops and make-to-order businesses. Now, Speed to Market delivers a proven approach for smaller suppliers who want to successfully cut their lead time and trigger profitable growth. Completely updated and expanded, the book explains how to: * Apply the principles of pull, flow, and the elimination of waste to every area of the company, at every stage from ""quotes to cash"" * Implement a continuous improvement process--while sidestepping the typical implementation pitfalls * Ease scheduling problems * Improve performance and profitability using the book's practical concepts, process analysis tools, and perspective-enhancing techniques--and much more."
Job Shop Lean
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Author : Shahrukh A. Irani
language : en
Publisher: CRC Press
Release Date : 2020-05-04
Job Shop Lean written by Shahrukh A. Irani and has been published by CRC Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2020-05-04 with Business & Economics categories.
In the 1950’s, the design and implementation of the Toyota Production System (TPS) within Toyota had begun. In the 1960’s, Group Technology (GT) and Cellular Manufacturing (CM) were used by Serck Audco Valves, a high-mix low-volume (HMLV) manufacturer in the United Kingdom, to guide enterprise-wide transformation. In 1996, the publication of the book Lean Thinking introduced the entire world to Lean. Job Shop Lean integrates Lean with GT and CM by using the five Principles of Lean to guide its implementation: (1) identify value, (2) map the value stream, (3) create flow, (4) establish pull, and (5) seek perfection. Unfortunately, the tools typically used to implement the Principles of Lean are incapable of solving the three Industrial Engineering problems that HMLV manufacturers face when implementing Lean: (1) finding the product families in a product mix with hundreds of different products, (2) designing a flexible factory layout that "fits" hundreds of different product routings, and (3) scheduling a multi-product multi-machine production system subject to finite capacity constraints. Based on the Author’s 20+ years of learning, teaching, researching, and implementing Job Shop Lean since 1999, this book Describes the concepts, tools, software, implementation methodology, and barriers to successful implementation of Lean in HMLV production systems Utilizes Production Flow Analysis instead of Value Stream Mapping to eliminate waste in different levels of any HMLV manufacturing enterprise Solves the three Industrial Engineering problems that were mentioned earlier using software like PFAST (Production Flow Analysis and Simplification Toolkit), Sgetti and Schedlyzer Explains how the one-at-a-time implementation of manufacturing cells constitutes a long-term strategy for Continuous Improvement Explains how product families and manufacturing cells are the basis for implementing flexible automation, machine monitoring, virtual cells, Manufacturing Execution Systems, and other elements of Industry 4.0 Teaches a new method, Value Network Mapping, to visualize large multi-product multi-machine production systems whose Value Streams share many processes Includes real success stories of Job Shop Lean implementation in a variety of production systems such as a forge shop, a machine shop, a fabrication facility and a shipping department Encourages any HMLV manufacturer planning to implement Job Shop Lean to leverage the co-curricular and extracurricular programs of an Industrial Engineering department
How To Implement Lean Manufacturing
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Author : Lonnie Wilson
language : en
Publisher: McGraw Hill Professional
Release Date : 2009-07-06
How To Implement Lean Manufacturing written by Lonnie Wilson and has been published by McGraw Hill Professional this book supported file pdf, txt, epub, kindle and other format this book has been release on 2009-07-06 with Technology & Engineering categories.
A Practical, Hands-on Guide to Lean Manufacturing This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made. How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to: Rigorously test and retest the state of your "leanness" with unique evaluators Develop and deploy plant-wide strategies and goals Improve speed and quality and dramatically reduce costs Reduce variation in the manufacturing system in order to reduce inventory Reduce lead times to enable improved responsiveness and flexibility Synchronize production and supply to the customer Create flow and establish pull-demand systems Perform system-wide and specific value-stream evaluations Generate a comprehensive list of highly focused Kaizen activities Sustain process gains Manage constraints and reduce bottlenecks Implement cellular manufacturing
Lean Supply Chain Management Essentials
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Author : Bill Kerber
language : en
Publisher: CRC Press
Release Date : 2011-06-27
Lean Supply Chain Management Essentials written by Bill Kerber and has been published by CRC Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2011-06-27 with Business & Economics categories.
Presenting an alternate approach to supply chain management, Lean Supply Chain Management Essentials: A Framework for Materials Managers explains why the traditional materials planning environment, typically embodied by an Enterprise Resource Planning (ERP) system, is an ineffective support system for a company that wants to adopt Lean practices. It begins by defining supply chain management basics, including roles, objectives, and responsibilities from a traditional framework. Next, it describes Lean basics and explores the conflicts between Lean and the traditional framework. The book focuses on the materials management aspects of Lean, such as leveling work into the value stream, heijunka scheduling, standard work, and the concept of intervals, including Every Part Every Interval (EPEI). By combining traditional materials management tools, such as Sales and Operations Planning (S&OP), with Lean manufacturing approaches and applying them to different manufacturing environments, the authors clarify the logic behind why you are doing what you’re doing with Lean components and how they fit together as a system. Specifically, they explain how to: Determine which leveling strategy to use to smooth production Calculate interval to determine lot sizes in various production environments Apply Lean to purchasing, warehouse, and logistics areas Use your value stream map for green initiatives and risk management Replace capacity planning and shop floor control with visual factory, operator balance charts, EPEI, and plan for every part Illustrating why balancing demand and capacity is better than trying to balance supply and demand, the book includes a definitive chart that matches Lean tools to the planning and control charts that have served as the model for ERP systems. It integrates the principles learned from Toyota’s fifty-plus-year journey with Lean principles to provide the up-to-date understanding required to approach the application of Lean to your supply chain with a methodology that allows for experimentation, learning, and continuous improvement.
Grow Your Factory Grow Your Profits
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Author : Timothy McLean
language : en
Publisher: CRC Press
Release Date : 2014-12-03
Grow Your Factory Grow Your Profits written by Timothy McLean and has been published by CRC Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2014-12-03 with Business & Economics categories.
When I was first given the job of managing a small plastics factory back in 1989, I quickly realized that most of the books and teaching on Lean Manufacturing were designed for big companies and were not relevant to my factory. —Tim Mclean The last 25 years has seen Tim lead and assist over 100 small to medium-sized enterprise (SME) manufacturing operations. This experience has now been condensed in to Grow Your Factory, Grow your Profits: Lean for Small and Medium-Sized Manufacturing Enterprises, a start-to-finish guide on how to run a successful small and medium-sized manufacturing operation. The book presents case studies, practical examples, illustrations, charts, and pictures from real SME manufacturers to provide straightforward solutions to the issues facing every growing manufacturing business. In the book, Tim McLean explains: How to recruit the right people and design the right organization How to empower those people to take accountability and free yourself up from day to day "fire fighting" How to develop a Lean Plant Layout that will maximize productivity and optimize the use of space How to manage materials in order to slash inventory and shortages How to schedule production in order to cut lead times, cut inventory, and delight customers How to get started on a Lean transformation when you lack the resources of a big company The book details how SMEs differ from large organizations and why the approach to improvement must also be different. Covering the complete life cycle of small and medium-sized manufacturers, the book addresses a different SME manufacturing issue in each chapter. This enables readers to tackle issues at their own pace and in their own order of priority. Grow Your Factory, Grow Your Profits is essential reading for owners, managers, and operational leaders in the 90 percent of manufacturing enterprises that are small or medium sized.
Mr Lean Buys And Transforms A Manufacturing Company
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Author : Greg Lane
language : en
Publisher: CRC Press
Release Date : 2009-12-17
Mr Lean Buys And Transforms A Manufacturing Company written by Greg Lane and has been published by CRC Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2009-12-17 with Business & Economics categories.
This is the true story of how, armed with only Lean improvement methodologies, a specially trained Toyota Lean expert purchased a business he knew nothing about, applied Lean techniques, and succeeded in doubling sales and increasing profitability, before he finally sold the thriving business. With humility and humor, the author recounts his successes and failures, introduces his key employees and their struggles with change, and provides motivation and simple ideas for all readers looking to improve their businesses. He captures key points highlighted in text boxes and includes illustrative photos and examples of Lean tools at work. This story dispels the fallacy that Lean management does not achieve excellent results in high variation companies and job shops. Toyota’s OSKKK methodology is introduced to understand processes and guide a Lean transformation on the shop floor and in the office.
Lean For High Mix Low Volume Manufacturers
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Author : Shahrukh Irani
language : en
Publisher: Productivity Press
Release Date : 2016-05-15
Lean For High Mix Low Volume Manufacturers written by Shahrukh Irani and has been published by Productivity Press this book supported file pdf, txt, epub, kindle and other format this book has been release on 2016-05-15 with Business & Economics categories.
The book integrates tehniques from the Toyota Production System (TPS) that apply to high-mix low-volume with the science of Group Technology and Cellular Manufacturing (GT/CM) to replace those parts of theTPS that pertain solely to high-volume, repeatable processes. GT/CM is the technical solution to Lean for high-mix low-volume. Toyota provides the tools to sustain GT/CM, especially the workforce culture and Lean leadership aspects
Lean Maintenance
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Author : Javier Girón Blanco
language : en
Publisher: Taylor & Francis
Release Date : 2018-01-29
Lean Maintenance written by Javier Girón Blanco and has been published by Taylor & Francis this book supported file pdf, txt, epub, kindle and other format this book has been release on 2018-01-29 with Business & Economics categories.
The book is about applying Lean manufacturing principles to industrial maintenance in order to improve the efficiency and be able to do more with the same (or less) resources. By industrial maintenance we mean the maintenance that takes place in factories and industrial facilities. The book is the result of multiple improvement projects carried out by the authors in various industrial settings and sectors in the past 10 years.The approach works and can be applied in any industry. It yields results without investment. The book is a step-by-step guide that takes the reader through the maintenance process, from equipment failure to finished repair. In each step of the process, the typical inefficiencies are explained and tools are given to improve the process. The book is meant to be used as a guide in an improvement journey. The improvement approach presented in the book is very close to the shop floor and instructs the reader to engage with all team members in the maintenance department in every step of the process, in order to make the improvements sustainable. If one looks at the main market indexes, between one third and one half of companies on those indexes belong to the industrial sector: automotive, power generation, basic materials, chemicals, consumer goods, et cetera. Those companies spend on average 2 – 5% of plant replacement value per year on maintenance. About one third of this cost is maintenance labor. The maintenance work that gets done every day in factories around the world is typically inefficient, from a Lean perspective: time is wasted, different tasks are not properly coordinated, job durations are overestimated and job plans, when they exist, are thus "inflated" to cover up the inefficiency. All this happens because maintenance tends to be the "forgotten" area of efficiency in industrial companies, as much of the improvements are carried out on the (literally) productive areas of the factories. When companies set out to "improve" maintenance, they typically do it through budget cuts that can risk the reliability of the equipment. The authors believe there is a better way to do more with the same resources through a careful review of the current way of working and the introduction of Lean. With this book , the authors try to bring to maintenance managers and practitioners the tools they need to quickly improve efficiency (in a matter of weeks) without any investment.
Lean Distribution
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Author : Kirk D. Zylstra
language : en
Publisher: John Wiley & Sons
Release Date : 2012-06-19
Lean Distribution written by Kirk D. Zylstra and has been published by John Wiley & Sons this book supported file pdf, txt, epub, kindle and other format this book has been release on 2012-06-19 with Business & Economics categories.
"Kirk Zylstra's focus on the customer is a fresh approach to lean. Companies that can bear the burden of variability will develop a strategic advantage in today's volatile market." —Travis Jarrell Institute of Industrial Engineers Program Committee Chair "Lean Distribution is a comprehensive yet concise work with clear leanings. Kirk's experience across a range of industries brings a unique understanding of common opportunities and solutions available to optimize distribution processes. Lean techniques, typically effective in manufacturing processes, are applied in the downstream supply chain in a practical and productive manner that will offer something to any business distributing tangible goods." —F. Jeff Duncan Jr. VP, CIO, and Director of Technology Louisiana Pacific Corp. "Lean Distribution has robustly captured the revolution occurring in today's increasingly competitive and global supply chain. Eliminating losses through lean manufacturing and lean distribution initiatives will become even more critical enablers to organizations developing cost-advantaged supply chains." —Rick McDonald Director of Manufacturing The Clorox Company