World Class Manufacturing Casebook


Book Description

This casebook, designed as a companion volume to Richard J. Schonberger's "World Class Manufacturing: The Lessons of Simplicity Applied," contains 26 cases that let students of WCM concepts solve actual JIT and TQC implementation problems in a wide variety of manufacturing and corporate settings. For readers with specific concerns, each case lists the topics covered (i.e., kanban, total preventive maintenance, partnership with customer) and each case includes questions on issues that companies commonly face in implementing WCM concepts. Dr. Schonberger also explains two JIT and TQC concepts not previously published -- micro-JIT analysis of shop-floor conditions by ratios and the "naturalistic" approach to quality improvement.




World Class Manufacturing Casebook


Book Description

This casebook, designed as a companion volume to Richard J. Schonberger's World Class Manufacturing: The Lessons of Simplicity Applied, contains 26 cases that let students of WCM concepts solve actual JIT and TQC implementation problems in a wide variety of manufacturing and corporate settings. For readers with specific concerns, each case lists the topics covered and each case includes questions on issues that companies commonly face in implementing WCM concepts.




World Class Manufacturing


Book Description

In his best-selling book Japanese Manufacturing Techniques, Richard J. Schonberger revolutionized American manufacturing theory and, more important, practice. In that breakthrough book, he revealed that Japanese manufacturing excellence was not culturally bound. Offering the first demystified explanation of the simple techniques that fueled Japan's industrial success, he demonstrated how the same methods could be put to work as effectively in U.S. plants.




Learning to Change


Book Description

Manufacturing firmsâ€"large and smallâ€"face massive change and adjustment as they move from a stable, fault-tolerant environment of long production runs to a volatile world in which production runs are short; product characteristics are changing constantly; and defect-free, on-time production at decreasing prices is a condition for survival. The necessary changes in the production organization include everything from the layout of the shop floor to the distribution of authority between managers and workers. The magnitude of these changes threatens to overwhelm the managerial capacities of firms, regardless of their size. This study examines the particularly vulnerable situation of small and mid-size manufacturers and considers ways in which to help them undertake the many changes and adjustments necessary. These include assimilating the new tools, disciplines, and philosophy of lean manufacturing; embracing new ways of delegating responsibilities; and developing new kinds of partnerships among customers, suppliers, and employees.




Lean Production for Competitive Advantage


Book Description

Lean Production for Competitive Advantage: A Comprehensive Guide to Lean Methodologies and Management Practices, Second Edition introduces Lean philosophy and illustrates the effective application of Lean tools with real-world case studies. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, pull production, preventive maintenance, standard work, as well as synchronizing and scheduling Lean operations. Detailing the key principles and practices of Lean production, the text also: Illustrates effective implementation techniques with case studies from a range of industries. Includes questions and completed problems in each chapter. Explains how to effectively partner with suppliers and employees to achieve productivity goals Designed for students who have a basic foundation in production and operations management, the text provides a thorough understanding of the principles of Lean. It also offers practical know-how for implementing a culture of continuous improvement on the shop floor and in the office, creating a heightened sense of responsibility in all stakeholders, and enhancing productivity and efficiency to improve the bottom line. In this second edition, the author addresses management’s role in Lean production. Early observers of Japanese methods focused on the shop floor to see amazing things unlike anything practiced elsewhere. And the thinking was, if the "methods" could be adopted by companies elsewhere, those companies would experience the success of the Japanese. What the early observers hadn’t considered were dramatic differences in the way those companies were managed, both daily and strategically. The "management side" of Lean production is addressed in two new chapters, one devoted to daily management, the other to strategy deployment. Additionally, there is a new chapter that addresses breakthrough improvement and an approach to achieving it called Production Preparation Process. Every chapter has been revised and expanded to better tell the story of Lean production—its history, applications, practices, and methods.




Kaikaku


Book Description

Foreword. . . Foreword. . Ch. 1. The journey begins. 5. Ch. 2. Introducing Dr. Shigeo Shingo. 15. Ch. 3. Taichi Ohno. 27. Ch. 4. Defining waste. 39. Ch. 5. Dr. Shingo asking five whys at Granville Phillips. 45. Ch. 6. My first trip to Japan : a thriller. 49. Ch. 7. Discovering Shingo : a magic moment. 63. Ch. 8. The lobster feast and the first changeover by Dr. Shingo. 71. Ch. 9. The study mission process. 85. Ch. 10. SMED - quick changeovers - the heart of JIT. 93. Ch. 11. My mental transformation : there are 'gems' scattered all over Japan. 103. Ch. 12. Developing an understanding of Japan. 121. Ch. 13. Factory tours : a feast for the eyes. 127. Ch. 14. The Gemba walk. 137. Ch. 15. 5 S. 143. Ch. 16. Discovering books in Japan. 147. Ch. 17. Fire the quality manager!. 155. Ch. 18. The best factory in the world. 161. Ch. 19. Getting to know Dr. Shingo. 171. Ch. 20. The birth of the Kaizen Blitz. 177. Ch. 21. Finding books and meeting Kazuhiro Uchiyama. 187. Ch. 22. Shingo to teacher. 193. Ch. 23. Never take no for an answer. 197. Ch. 24. Introduction to TPM - another billion dollar idea. 201. Ch. 25. Shigehiro Nakamura. 213. Ch. 26. Kaoru Ishikawa. 227. Ch. 27. Iwao Kobayashi - 20 keys. 231. Ch. 28. Union of Japanese scientists and engineers (JUSE). 235. Ch. 29. Dr. W. Edwards deming. 237. Ch. 30. The impact of Dr. Joseph Juran. 251. Ch. 31. Life time employment system. 253. Ch. 32. Quick and easy Kaizen. 257. Ch. 33. A gallery of great geniuses. 277. Ch. 34. Professor Louis E. Davis and socio-technical systems. 295. Ch. 35. Failure to change is a vice!. 301. Ch. 36. Summary. 305. Ch. 37. Gary Convis - President Toyota (TMMK). 307. Ch. 38. Gary Smuda - technicolor corporation. 319. Ch. 39. Professor Doc - Robert Hall. 329. Ch. 40. Don Dewar - President QCI International. 341. Ch. 41. Richard Schonberger. 345. Ch. 42. Vision statements. 355. . Lean terms. 361.




Innovations in Competitive Manufacturing


Book Description

Innovations in Competitive Manufacturing is an examination of manufacturing innovations - both technical and knowledge-based. Over the recent past, technology has created dramatic changes in manufacturing. As a result, the book focuses on the use of technology in gaining competitive advantage in global manufacturing. Forty topics are surveyed in the book, organized into thirteen chapters. Each topic is a carefully written account by one or more leading researchers in that area. This is the first systematic examination of the recent innovations in manufacturing strategy and technology. In addition to providing an understanding of these manufacturing innovations, the book underscores the strategic importance of creating and sustaining the technological resources to ensure a stable manufacturing economic base. The book's purpose is to examine the elements that make today's manufacturers successful. Many examples from industry throughout the book will enable the reader to appreciate and comprehend the concepts presented in the article. In addition to the technical and innovative information, implementation issues concerning new ideas and manufacturing practices are explored within the topical discussions. Four in-depth descriptions of real-life cases provide illustration of key principles. The book has been constructed as a reference tool for manufacturing researchers, students, and practitioners. Hence, after reading the introduction `Innovation in Competitive Manufacturing: From JIT to E-Business', any section or topic in the book can be consulted and/or read in any sequence the reader may choose.




Effective Transition from Design to Production


Book Description

Taking a new product from the design stage to large-scale production in a profitable, efficient manner can challenge the processes of even the most advanced companies. Lapses in these processes drive up the cost of new products, and hinder their launch into the marketplace. Effective Transition from Design to Production provides an expeditio




Building a Chain of Customers


Book Description

Richard Schonberger, in his fourth and most important book yet, introduces a powerful new concept: that the many links between and within the four main business functions -- design, operations, accounting, and marketing -- form a continuous "chain of customers" that extends to those who buy the product or service. Everyone has a customer -- the next department, office, shop, or person -- at the hundreds of pioneering companies Schonberger has studied throughout the world. Schonberger demonstrates the universality of customer wants: Both the next and final customers want ever better quality, quicker response, greater flexibility, and lower cost. This condition provides a common strategy and calls for common methods to be used across the organization. Every employee is a data gatherer and analyst, unearthing more and better ways to provide for these customers' wants -- before the competition does so. As the new thinking and methods permeate every comer of the firm, they topple departmental walls and adjust gang-like mind-sets and "them-versus-us" attitudes. Performance is no longer measured by internal costs but by improvement as seen by the next customer; direct control of causes generally replaces after-the-fact control of costs. Design is brought out of isolation. Finally, with the rest of the firm reoriented toward customer service, marketing escapes from a "negative" mode -- covering up for failures -- to a positive one -- crowing about the firm's competence and ability to improve. With the close attention to detail for which he has become famous, Schonberger constructs a blueprint for unifying corporate functions, brilliantly describing the new microcosms that will make up the company of the 1990s -- focused teams of multi-skilled, involved employees arranged according to the way the work flows or the service is provided -- that compose the chain of customers. Aetna, for example, is organizing customer-focused teams that cut across underwriting and the administrative functions. At Hewlett-Packard, teams of marketing, manufacturing, and R&D people have already gone through several iterations of "activity-based costing", which provides product designers with previously unavailable data for shaving costs throughout product life cycles. And at Du Pont, even production people on the factory floor are involved in assessing competitors' product quality and probable costs and methods. Through these and hundreds of other real company examples, Schonberger shows how the customer-driven chain of action leads directly to the kinds of bottom-line performance that have been so elusive to executives who manage at a distance "by the numbers" -- namely, higher profits, greater security, and gains in market share at the expense of the laggard competion.




Concepts, Applications and Emerging Opportunities in Industrial Engineering


Book Description

From their initial focus in manufacturing, the industrial engineering principles, tools, and techniques have spread across a spectrum of application areas. Topics covered in this book apply to this continuum of application, including operations planning, safety, quality, production control, inventory management, operations research, supply chain management, and continuous improvement. This edited book comes at an opportune time. It incorporates new knowledge and expertise in a rapidly changing engineering discipline that is a vital force in a wide range of manufacturing, service, educational, and government organizations. Such concepts as lean systems, sustainability, systems thinking, data analytics, and additive manufacturing, as well as utilization of advanced computer software, have further expanded industrial engineering's breadth. Each chapter reflects important aspects of these advances.