Author : Hiroyuki Hirano
Publisher : CRC Press
Page : 189 pages
File Size : 47,54 MB
Release : 2009-04-27
Category : Business & Economics
ISBN : 1420090259
"It is a book for manufacturing companies that are fighting desperately for survival and that will go to any length to improve their factories and overcome the obstacles to success. One could even call this book a bible for corporate survival."Hiroyuki Hirano Known as the JIT bible in Japan, JIT Implementation Manual The Complete Guide t
Author : Y. Monden
Publisher : Springer Science & Business Media
Page : 427 pages
File Size : 39,53 MB
Release : 2012-12-06
Category : Science
ISBN : 1461597145
The Just-in-time (JIT) manufacturing system is an internal system in use by its founder, Toyota Motor Corporation, but it has taken on a new look. Toyota Production System, Second Edition systematically describes the changes that have occurred to the most efficient production system in use today. Since the publication of the first edition of this book in 1983, Toyota has integrated JIT with computer integrated manufacturing technology and a strategic informa tion system. The JIT goal of producing the necessary items in the necessary quantity at the necessary time is an internal driver of production and operations management. The addition of computer integrated technology (including expert systems by artificial intelligence) and information systems technology serve to further reduce costs, increase quality, and improve lead time. The new Toyota production system considers how to adapt production schedules to the demand changes in the marketplace while satisfying the goals of low cost, high quality, and timely delivery. The first edition of this book, Toyota Production System, published in 1983, is the basis for this book. It was translated into many languages including Spanish, Russian, Italian, Japanese, etc., and has played a definite role in inspiring production management systems throughout the world.
Author : Mohammed Hamed Ahmed Soliman
Publisher : Mohammed Hamed Ahmed Soliman
Page : 265 pages
File Size : 11,51 MB
Release :
Category : Business & Economics
ISBN :
Yes, people called Toyota Production System an inventory reduction program when they first heard of it. “Just in time” is one of the main pillars in the TPS. “Just in time” ideally means “one-piece flow.” Inventory is the greatest waste in the process, and it hides many problems, such as quality problems, breakdown times, waiting waste, and more. Let’s get back to history. Prior to the 1970 oil crisis, very few people in the world know what Toyota was up to. The fact that it emerged stronger than ever while many of its competitors were quite battered made people take notice. People went to Japan to find out how Toyota had done this. What people found was that Toyota was doing something called “just in time.” In the West, this was interpreted as an inventory reduction program. As a result, it became known as the “just-in-time inventory” program. Nobody really believed inventory could be taken out of the whole value stream. Therefore, “just in time” came to mean “go beat the heck out of your suppliers.” The big three auto companies (Ford, General Motors, and Chrysler) had lots of power over their suppliers, and they became pretty expert at this tactic—to their eventual detriment. James P. Womack came forward with Lean Thinking in 1996 and helped many to see the whole value chain. He showed how waste clogs the system and how continuous improvement was needed to link all parts of the chain to customer demand. He explained his findings in plain English, but once again people didn’t hear. Lean might be an element of the larger strategy, but it is most likely to be relegated to plant and manufacturing work. As a result, one company after another has tried lean and failed. Many people believe that just-in-time inventory equals zero inventory. The ideal situation is one-piece flow, which can only be achieved through the use of a manufacturing cell. The inventory buffer exists, but it is rarely used. The Andon system includes a buffer. There is a safeguard in place to protect your customer. There is a buffer to prevent the entire manufacturing line from being shut down to rectify a problem. There is a buffer in place to prevent the breakdown of a vital manufacturing process. Just-in-time production is a manufacturing system that produces and delivers only what is required, only when it is required, and only in the amount required. The Toyota Production System is built on two pillars: JIT and jidoka. JIT is based on heijunka and consists of three operating elements: the pull system, takt time, and continuous flow.
Author : Rajan Suri
Publisher : CRC Press
Page : 232 pages
File Size : 15,90 MB
Release : 2010-03-31
Category : Business & Economics
ISBN : 1439805962
In the decade since the publication of Rajan Suri’s landmark book, Quick Response Manufacturing, the innovative principles of QRM have been proven with impressive results at many companies, big and small, in a variety of industries. While the key principles of QRM remain unchanged, after a decade of teaching QRM workshops to senior executives, Suri has developed a clear, concise, and accessible method of presenting QRM strategy using four core concepts: 1. The Power of Time – the huge impact time has on your entire enterprise 2. Organization Structure – how to structure your organization to reduce lead times 3. System Dynamics – understanding how interactions between jobs and resources impact time to make better decisions on capacity, lot sizes, and similar issues 4. Enterprise-Wide Application – QRM is not just a shop floor strategy, it extends across your whole enterprise including material planning and control, supply management, office operations, and new product introduction Presenting new case studies on QRM implementation, It's About Time: The Competitive Advantage of Quick Response Manufacturing illustrates how QRM can not only reduce lead times but also improve quality, reduce operating costs, and enable companies to gain substantial market share. This practical reference explains how factories in advanced nations can use QRM strategy to compete with manufacturers in low-wage countries. In addition, it provides helpful pointers for QRM implementation, including accounting strategies, novel cost-justification approaches, and a stepwise process for implementation. Also included are downloadable resources with five appendices that provide a number of practical details to assist in the success of your QRM implementation. When you are ready to start implementing QRM, you will find that these appendices contain time-saving tips to help you work through implementation issues¿including simple calculation methods and tools to support the design of your QRM strategy. You can also access these Appendices on the Downloads and updates tab on https://www.crcpress.com/9781439805961. The author, Rajan Suri, recently became one of only 10 people to be inducted into Industry Week's 2010 Manufacturing Hall of Fame.
Author : Productivity Press Development Team
Publisher : CRC Press
Page : 118 pages
File Size : 39,93 MB
Release : 2020-06-29
Category : Business & Economics
ISBN : 1000005186
Kanban is the name given to the inventory control card used in a pull system. The primary benefit of kanban is to reduce overproduction, the worst of the seven deadly wastes. A true kanban system produces exactly what is ordered, when it is ordered, and in the quantities ordered. It is essentially a dynamic work order that moves with the material. Each kanban identifies the part or subassembly unit and indicates where each one came from and where each is going. Used this way, kanban acts as a system of information that integrates your plant, connects all processes one to another, and connects the entire value stream to customer demand. Kanban for the Shopfloor provides a working manual for those seeking to implement this method of production control in any operation. It defines the various terms and methods employed in kanbans, and illustrates how when adhered to, kanban is an element of continuous improvement that ultimately leads to the ideal of one-piece flow." In addition to reducing the waste of overproduction, kanban will help your company increase flexibility to respond to customer demand, coordinate production of small lots and wide product variety, and simplify the procurement process. About the Shopfloor Series: Put proven improvement tools in the hands of your entire workforce! Progressive shopfloor improvement techniques are imperative for manufacturers who want to stay competitive and to achieve world class excellence. And it's the comprehensive education of all shopfloor workers that ensures full participation and success when implementing new programs. The Shopfloor Series books make practical information accessible to everyone by presenting major concepts and tools in simple, clear language and at a reading level that has been adjusted for operators by skilled instructional designers. One main idea is presented every two to four pages so that the book can be picked up and put down easily. Each chapter begins with an overview and ends with a summary section. Helpful illustrations are used throughout. Other topics in the Shopfloor Series: Kanban, 5S, Quick Changeover, Mistake-Proofing, Just-in-Time, TPM, Cellular Manufacturing
Author : Alin Posteucă
Publisher : CRC Press
Page : 305 pages
File Size : 29,38 MB
Release : 2023-02-16
Category : Business & Economics
ISBN : 1000836363
Currently, the challenge for manufacturing organizations is how to achieve their expected profit by continuously improving productivity or reducing costs. Manufacturing organizations have been using different improvement approaches to achieving cost reduction and productivity improvement for years by eliminating various losses and waste structures, such as excess inventory, excessive workforce, excessive capacity, excessive utility consumption, and so on. But is the problem solved? Unfortunately, no! Often manufacturing companies focus on maximizing the flow and meeting customer needs but forget their real aim – to make a profit for their stakeholders. Too many organizations meet customer expectations by seeking to continuously synchronize the flow to market demand but forget to check that they are doing it profitably enough to ensure business continuity and prosperity. When the financial results show that they are not so profitable, it is already too late. Moreover, the strategic direction of systematic improvements according to the sales trend – depending on the current degree of production capacity utilization and its dynamic effects on cost structures – is deficient in many manufacturing companies. So, would the failure of strategic and profitable systematic improvements be an option? Of course not! If the ultimate goal of the organization is to create target profit for stakeholders, then the behavior and strategic systematic improvements must be directed to those scenarios, strategies, tasks, problems, and “production levers” that are best based on creating the target profit. That’s what Strategic Kaizen thinking does – the simultaneous and consistent achievement of systematic operational and financial improvements in a strategic and operational manner. It achieves both synchronous operations at market demand by fulfilling takt time and profitable operations in accordance with profit demand by fulfilling takt profit. In short, the Strategic Kaizen mission is striving for the fulfillment of the ideal state of operations called synchronous profitable operations. In this book, the author, while presenting in detail the seven processes of Strategic Kaizen methodology, exposes the answer to historically incomplete thinking of productivity improvements for target profitability. The uniqueness of the book is reinforced by the detailed presentation of the successful application of the Strategic Kaizen thinking over the years in two multinational manufacturing organizations operating in highly competitive markets, addressing the synchronous profitable operations for both the sales increase scenario and the sales decrease scenario. Moreover, it presents examples of the practical application of the “white-collar” Strategic Kaizen. Essentially, by adopting the Strategic Kaizen methodology presented in detail in this book to consistently achieve the ideal state of a manufacturing organization, organizations will enter a new paradigm of thinking of strategic improvements – Strategic Kaizen thinking – to meet annual and multiannual target profits in a unique and effective way that operates according to its own strategic and operational management system.
Author : Prabir Jana
Publisher : Woodhead Publishing
Page : 454 pages
File Size : 12,73 MB
Release : 2021-02-17
Category : Technology & Engineering
ISBN : 0128194278
The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead. - An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing - Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants - Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician's delight - Possible use cases of several lean tools having potential use in the apparel manufacturing scenario
Author : Rajkishore Nayak
Publisher : Springer Nature
Page : 321 pages
File Size : 22,2 MB
Release : 2022-08-29
Category : Technology & Engineering
ISBN : 9811921083
This book highlights the concepts of lean manufacturing that help to achieve the objectives of sustainability in a global competitive atmosphere. Lean can help to lower the manufacturing cost in the rising labour and material cost market. Lean is based on various fundamental concepts such as Kaizen, Kanban, Zidoka, 5S and Six Sigma, which aim at reducing process waste for efficiency and productivity that are discussed in this book. In addition, the technological changes such as introduction of Internet technologies and Industry 4.0 are taken care by the lean concepts, which are also addressed in this book.
Author : Michel Baudin
Publisher : Taylor & Francis
Page : 800 pages
File Size : 26,78 MB
Release : 2022-12-27
Category : Business & Economics
ISBN : 1351110306
This Introduction to Manufacturing focuses students on the issues that matter to practicing industrial engineers and managers. It offers a systems perspective on designing, managing, and improving manufacturing operations. On each topic, it covers the key issues, with pointers on where to dig deeper. Unlike the many textbooks on operations management, supply chain management, and process technology, this book weaves together these threads as they interact in manufacturing. It has five parts: Getting to Know Manufacturing: Fundamental concepts of manufacturing as an economic activity, from manufacturing strategy to forecasting market demand Engineering the Factory: Physical design of factories and processes, the necessary infrastructure and technology for manufacturing Making Information Flow: The "central nervous system" that triggers and responds to events occurring in production Making Materials Flow: The logistics of manufacturing, from materials handling inside the factory via warehousing to supply chain management Enhancing Performance: Managing manufacturing performance and methods to maintain and improve it, both in times of normal operations and emergencies Supported with rich illustrations and teaching aids, Introduction to Manufacturing is essential reading for industrial engineering and management students – of all ages and backgrounds – engaged in the vital task of making the things we all use.
Author : Rajan Suri
Publisher : CRC Press
Page : 575 pages
File Size : 21,32 MB
Release : 2020-10-28
Category : Business & Economics
ISBN : 1482278103
Developed by the author and now being employed by a number of businesses, Quick Response Manufacturing (QRM) is an expansion of time-based competition, aimed at a single target with the goal of reducing lead times. The key difference between QRM and other time-based programs is that QRM covers an entire organization, from the shop floor to the office, to sales and beyond. Providing guidelines for establishing a QRM enterprise, this volume builds upon kaizen, TQM, TPM, and other practice to help organizations streamline all functions of their operation. It shows how to quickly introduce products, along with ways to rethink materials and production management.
