Download or read book A Complete Guide to Just in Time Production Inside Toyota s Mind written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2023-09-28 with total page 265 pages. Available in PDF, EPUB and Kindle. Book excerpt: Yes, people called it 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.

Download or read book JIT Implementation Manual The Complete Guide to Just In Time Manufacturing written by Hiroyuki Hirano and published by CRC Press. This book was released on 2009-04-27 with total page 189 pages. Available in PDF, EPUB and Kindle. Book excerpt: "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

Download or read book Toyota Production System written by Y. Monden and published by Springer Science & Business Media. This book was released on 2012-12-06 with total page 427 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book It s About Time written by Rajan Suri and published by CRC Press. This book was released on 2010-03-31 with total page 232 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Kanban for the Shopfloor written by Productivity Press Development Team and published by CRC Press. This book was released on 2020-06-29 with total page 118 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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

Download or read book Beyond Strategic Kaizen written by Alin Posteucă and published by CRC Press. This book was released on 2023-02-16 with total page 305 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Lean Tools in Apparel Manufacturing written by Prabir Jana and published by Woodhead Publishing. This book was released on 2021-02-17 with total page 454 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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

Download or read book Lean Supply Chain Management in Fashion and Textile Industry written by Rajkishore Nayak and published by Springer Nature. This book was released on 2022-08-29 with total page 321 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Introduction to Manufacturing written by Michel Baudin and published by Taylor & Francis. This book was released on 2022-12-27 with total page 800 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Essentials of Inventory Management written by Max Muller and published by AMACOM Div American Mgmt Assn. This book was released on 2011 with total page 272 pages. Available in PDF, EPUB and Kindle. Book excerpt: Does inventory management sometimes feel like a waste of time? Learn how to maximize your inventory management process to use it as a tool for making important business decisions.

Download or read book Quick Response Manufacturing written by Rajan Suri and published by CRC Press. This book was released on 2020-10-28 with total page 575 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.

Download or read book Increasing Supply Chain Performance in Digital Society written by Leon, Ramona Diana and published by IGI Global. This book was released on 2022-06-03 with total page 379 pages. Available in PDF, EPUB and Kindle. Book excerpt: Currently, the main operations of companies are either directly or indirectly interconnected in a global-world context. Competition has drifted from an individual to a supply chain basis, where digitalization plays a key role. Companies with better digital capabilities achieve sustainable competitive market advantages. In this context, companies must identify their current position in terms of digital capabilities, link these capabilities to supply chain performance, define their future desired competitive position and how their digital capabilities are going to help them to get there, and forecast their future desired performance not only at the individual company but also at the supply chain level. Increasing Supply Chain Performance in Digital Society considers innovative approaches to measure, manage, and project towards the future of the digital capabilities of both individual companies and supply chains. It also examines the relations these have with performance being a practical tool to identify not only where they are today in terms of digital capabilities but also where they should be long term and the resources needed to get them there. Covering a range of topics such as artificial intelligence and risk management, this reference work is ideal for practitioners, researchers, scholars, business owners, industry professionals, academicians, instructors, and students.

Download or read book A Complete Guide to Energy Savings In a Domestic Household 2020 Edition written by C. B. Hotnoga and published by Lulu.com. This book was released on 2020-01-03 with total page 86 pages. Available in PDF, EPUB and Kindle. Book excerpt: Save BIG on your energy and water bills. Any household can lead exactly the same lifestyles whilst cutting down at least 25%% on energy and water expenses, and helping the Environment at the same time. A complete Guide to maximum energy (electricity and gas) + water savings in a domestic household Part of Project "CHALLENGE" For the Future A better approach to energy savings Greener behaviours in modern day lifestyles Planning, ahead of changing Cutting down on natural resources used Reducing pollution Fighting climate change Making BIG SAVINGS on that energy bill Project "CHALLENGE" includes: Domestic households Small sized commercial premises Medium commercial businesses Medium and large commercial businesses with high energy demands Industrial premises

Download or read book The Comprehensive Guide to Brewing written by Gabriela Basarová and published by Fachverlag Hans Carl. This book was released on 2020-12-30 with total page 876 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Czech Republic is one of the motherlands of beer culture – beers of the pilsner brewing tradition and the aromatic Saaz hops are famous the world over. Brewing technicians and scientists from the Czech Republic have an excellent reputation and are constantly seeking an exchange and discussion of their research findings on the international scene. And the team of authors around Professor Basařová are all experienced technicians and scientists with a wealth of international experience. "The Comprehensive Guide to Brewing" is a unique groundwork for brewing technicians which deals with all subject areas, from the raw materials to packaging. It also conveys advanced knowledge of the fundamentals of brewing research. Compulsory reading for anyone who wishes to gain in-depth knowledge of brewing technology.

Download or read book A Lean Guide to Transforming Healthcare written by Tom Zidel and published by Quality Press. This book was released on 2006-04-14 with total page 194 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is an implementation manual for lean tools and principles in a healthcare environment. Lean is a growth strategy, a survival strategy, and an improvement strategy. The goal of lean is, first and foremost, to provide value to the patient/customer, and in so doing eliminate the delays, overcrowding, and frustration associated with the existing care delivery system. Lean creates a better working environment where what is supposed to happen does happen. On time, every time. It allows clinicians to spend more of their time caring for patients and improves the quality of care these patients receive. A lean organization values its employees and encourages their involvement in organizational initiatives which, in turn, sustains hospital-wide quality improvements. The opportunities for lean in healthcare are limitless. This is not a book to be read and forgotten, nor is it meant to sit on a book shelf as another addition to an impressive but underutilized collection of how-to books. As the name implies, it is a guide; a companion to be referenced again and again as the organization moves forward with its lean transformation. "This is a well-researched, well-written work by an individual who understands the current healthcare environment. It provides a practical and sound understanding of the concepts and application for Lean and Six Sigma." James R. Bente Vice President, Quality & Organizational Development Memorial Health System "Healthcare quality professionals in the U.S. and abroad could benefit from the content of this book...Comprehensive discussion of lean and its relevance to healthcare, excellent description of techniques and tools, and excellent examples and figures." Luc R. Pelletier, MSN APRN BC FNAHQ FAAN Editor in Chief Journal for Healthcare Quality COMMENTS FROM OTHER CUSTOMERS Average Customer Rating (4.5 of 5 based on 4 reviews) "This book is easy to read and demystifies the complex world of Lean by clearly explaining what Lean is, what it does, and the tools used; all in the context of healthcare. Because examples illustrate the benefit of Lean not just to the healthcare industry, but to us as patients, the business case is especially compelling. Instructions address technical challenges and draw from best practices in change management. The guide provides a road map for implementation and seasoned insights that leave one trusting that Lean is very doable, and a necessity." A reader in Seattle, Washington "I thoroughly enjoyed this book as it provides concrete and detailed examples of Lean principles applied to a healthcare environment. I myself am new to healthcare and am overwhelmed at the wealth of opportunities for improvement. I plan on using some lean principles to demonstrate that improvements don't have to be complex or costly to achieve results" A reader in Montreal, Quebec "This is an excellent resource. I consider it 'required reading' for all that are new to Lean / Process Improvement. In my role, I facilitate 5-10 concurrent process improvement projects. This book has been invaluable as a teaching tool. I've asked each project leader to buy, read and study this book. All have commented that it has an easy read, helped them to understand the Lean concepts, and quickly implement the tools. As a group, we're better able to speak the same language and have a common understanding of the tools.brI highly recommended this book. I would also recommend the website (www.leanhospitals.org), wh..." A reader in Wausau, Wisconsin

Download or read book The COMPLETE BOOK of Product Design Development Manufacturing and Sales written by Steven Selikoff and published by . This book was released on 2020-06-02 with total page 516 pages. Available in PDF, EPUB and Kindle. Book excerpt: - For beginners who are new to developing products and selling them- For experienced product developers looking to remove risks and fill in knowledge gaps- For inventors with new products seeking information on validation, manufacturing and sales channels- For Amazon Sellers looking to take the next step, to introduce unique products, grow into retailers, and expand their business. Complete step-by-step instructions on how to identify unique winning products, validate customer demand, ensure profitability, design and engineer your product, identify factories, negotiate effectively, manage shipping & logistics, and generate sales across all channels from independent retailers to chains and big box stores.

Download or read book Speed Based Target Profit written by Alin Posteucă and published by CRC Press. This book was released on 2020-11-19 with total page 390 pages. Available in PDF, EPUB and Kindle. Book excerpt: Profitable production planning is and will remain an eternal challenge to ensuring the prosperity and dignity of companies in a global market. Even though there are different approaches to achieving the target profitability through productivity in the production planning stage, these approaches do not guarantee consistent planning, creation, and sustenance of synchronous profitable operations for multiannual and annual target profit. In feedback to this predicament, Alin Posteucă develops a new system called speed-based target profit (SBTP). SBTP is the profitable production management and manufacturing improvement system that approaches production planning to achieve unit speed of target profit for target products through manufacturing cost improvement and bottleneck profitability control for maximum takt time. Managers and practitioners within manufacturing companies will discover a practical approach for cost down and cash up by applying a powerful operational profitable production planning formula to meet profitability expectations through productivity based on strong leadership with the help of a specific system for feedforward, concurrent, and feedback control. Therefore, the SBTP system in this book presents a holistic approach to profitability for target products and the development of its own mechanism since the acceptance of each order from customers to achieve continuous synchronization of all manufacturing processes to market requirements, profitability management, and profitable production planning. The uniqueness of the book is reinforced by a detailed presentation of the successful application of the SBTP system in two case studies, as a way of life and a unit speed of target profit improvement ethos at all hierarchical levels, in two multinational manufacturing companies operating in highly competitive markets in order to address the synchronous profitable operations for both the sales increase scenario and the sales decrease scenario. By adopting the SBTP system, your company will be able to consistently achieve unit speed of target profit in the bottleneck process for fulfilling annual and multiannual target profit as a unique and effective way through a new profitable production planning paradigm that operates according to its own production system.