Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer"If you are seriously interested in reducing costs and inventory while increasing revenue and customer satisfaction in a manufacturing environment, read this book." This proven, easy-to-understand “how to” manual gives you the progressive steps to factory transformation to Lean without the aid of a consultant. It provides a toolbox of techniques for problem solving, continuous improvement, and for operating a Lean manufacturing facility on a day-to-day basis after the initial line design is completed. The book also features Kanban strategies for managing inventory including Single-Card and Multiple-Card Kanban Systems. |
Contents
| 1 | |
The Popularity of MRP Systems and Their Impact on Organizations | 17 |
The Kanban Methodology | 28 |
Enter the Internet and eCommerce Technologies | 41 |
Performing a Strategic Business Analysis | 47 |
Important Performance Metrics for the | 53 |
Impact of Manufacturing Lead Time on Working Capital | 59 |
Understanding Your Products Processes and Demand | 65 |
Documenting Process Work Elements and Quality Criteria | 96 |
Summing the Total Time of the Process | 103 |
The Lean Approach to Achieving Balance | 109 |
Managing Inventory with the Kanban System | 159 |
Kanban Manager Job Responsibilities | 176 |
Required Information Overview | 194 |
Milestone 4 Factory Design | 208 |
Managing the Lean Manufacturing Line | 223 |
Establishing the Capacity to Meet the Demand Volume | 71 |
Factors Impacting Throughput Volume | 78 |
Identifying Process Demand Levels and Establishing Takt | 87 |
Resistance to Change | 236 |
Common terms and phrases
achieve action items amount assigned balance benefits bill of material capacity common completed configuration cost customer demand daily demand volume documented downstream process electronic kanban eliminated established factory facturing Figure finished goods inventory floor forecast goals identified implementation project implementation team inventory investment kaizen kanban containers kanban quantity labor Lean implementation Lean manufacturing line Lean manufacturing methodologies Lean methodologies machine machine cell manu manufac manufacturing facility manufacturing lead manufacturing processes material handlers Materials Team milestone mixed-product MRP system necessary nonvalue-added operators options output parent part numbers Pareto analysis perform planner planning system process flow diagram process identified process map produce product pull chain pull sequence purchased reduced replenishment point resource calculation response rework RIP location schedule scrap sequencing points setup shortages steering committee stockroom strategy supplier tasks team members techniques throughput volume two-bin unit workstation