Download or read book Lean for the Process Industries written by Peter L. King and published by CRC Press. This book was released on 2019-06-05 with total page 373 pages. Available in PDF, EPUB and Kindle. Book excerpt: Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

Download or read book Lean for the Process Industries written by Peter L. King and published by CRC Press. This book was released on 2019-06-05 with total page 260 pages. Available in PDF, EPUB and Kindle. Book excerpt: Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

Download or read book Liquid Lean written by Raymond C. Floyd and published by CRC Press. This book was released on 2010-02-24 with total page 331 pages. Available in PDF, EPUB and Kindle. Book excerpt: While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author‘s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of t

Download or read book Value Stream Mapping for the Process Industries written by Peter L. King and published by CRC Press. This book was released on 2017-08-25 with total page 240 pages. Available in PDF, EPUB and Kindle. Book excerpt: Providing a framework that highlights waste and its negative effects on process performance, value stream maps (VSMs) are essential components for successful Lean initiatives. While the conventional VSM format has the basic structure to effectively describe process operations, it must be adapted and expanded to serve its purpose in the process indu

Download or read book Lean for the Process Industries written by Peter L. King and published by Productivity Press. This book was released on 2012 with total page 358 pages. Available in PDF, EPUB and Kindle. Book excerpt: Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While, a number of innovators have successfully applied Lean principles to these industries over the last two decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on 40 years of application experience at one of the world's largest chemical and materials manufacturers, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity -Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operationsExplains how to adapt value stream mapping for process operationsShows how to identify the root causes of bottlenecks, and systemically eliminate themProvides process-oriented modifications that will enhance the usefulness of Cellular Manufacturing, Heijunka Production Leveling, and Pull Replenishment Systems Discusses the role of process operations management in a Lean strategy Whether you are manufacturing consumer products such as foods, paints, and pharmaceuticals, or materials such as bulk chemicals, sheet goods, and synthetic fibers, this book shows you how to achieve that enviable level of performance where continual improvement becomes inherent to your processes.

Download or read book Lean Production for the Small Company written by Mike Elbert and published by CRC Press. This book was released on 2018-02-19 with total page 295 pages. Available in PDF, EPUB and Kindle. Book excerpt: A hands-on guide to adapting Lean principles and the Toyota Production System to high-mix/low-volume environments, Lean Production for the Small Company uses charts, pictures, and easy-to-understand language to describe the methods needed to improve processes and eliminate waste. It walks readers through the correct order of implementation and desc

Download or read book People Process and Culture written by Jeffrey P. Wincel and published by CRC Press. This book was released on 2013-04-23 with total page 157 pages. Available in PDF, EPUB and Kindle. Book excerpt: Examining Lean processes in the context of the authors’ academic research in-progress, People, Process, & Culture: Lean Manufacturing in the Real World illustrates the impact of culture on the implementation of Lean Manufacturing (LM) across various geographic and cultural areas. It identifies cultural values, as examined against Lean manufacturing disciplines, and derives culturally based Lean Manufacturing (LM) values. It then assesses these cultural values in light of specific LM components, such as PULL systems and TPM, to demonstrate varying perspectives and applications. Illustrates global cultural influences on Lean implementation Uses academic research as the foundation of the material Examines the many Lean components currently in use around the world Building on the continued prominence of LM as the preferred operational approach, the book supplies time-tested advice to help you sort through the flood of information on Lean techniques and culture. It examines the numerous Lean components currently being deployed successfully around the world and identifies the limitations that can result from the varying interpretations and applications of Lean systems. Lean culture is all about Lean vision, mission, and values. This book not only identifies the Lean values required, but also supplies the understanding to integrate these values across all levels of your organization. The book will be especially helpful to international corporate managers working to demystify the sometimes hard-to-understand characteristics of Lean transformation.

Download or read book Lean Manufacturing that Works written by Bill Carreira and published by AMACOM/American Management Association. This book was released on 2005 with total page 324 pages. Available in PDF, EPUB and Kindle. Book excerpt: If your manufacturing organization is slow and inefficient, it's time to slim down. Here's a proven "weight loss" plan.

Download or read book Fundamental Principles of Lean Manufacturing written by Shigeo Shingo and published by . This book was released on 2017-02-28 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Fundamental Principles of Lean Manufacturingis the latest discovered and newly translated classic from Dr. Shigeo Shingo, engineering genius and a driving force behind the successful realization of the Toyota Production System and Lean Manufacturing. This first-time-in-translation book will give modern readers total access to the fundamentals of improving any process.

Download or read book Lean Thinking written by James P. Womack and published by Simon and Schuster. This book was released on 2013-09-26 with total page 400 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lean Thinking was launched in the fall of 1996, just in time for the recession of 1997. It told the story of how American, European, and Japanese firms applied a simple set of principles called 'lean thinking' to survive the recession of 1991 and grow steadily in sales and profits through 1996. Even though the recession of 1997 never happened, companies were starving for information on how to make themselves leaner and more efficient. Now we are dealing with the recession of 2001 and the financial meltdown of 2002. So what happened to the exemplar firms profiled in Lean Thinking? In the new fully revised edition of this bestselling book those pioneering lean thinkers are brought up to date. Authors James Womack and Daniel Jones offer new guidelines for lean thinking firms and bring their groundbreaking practices to a brand new generation of companies that are looking to stay one step ahead of the competition.

Download or read book Becoming Lean written by Jeffrey K. Liker and published by CRC Press. This book was released on 1997-11-12 with total page 570 pages. Available in PDF, EPUB and Kindle. Book excerpt: What is Lean? Pure and simple, lean is reducing the time from customer order to manufacturing by eliminating non-value-added waste in the production stream. The ideal of a lean system is one-piece flow, because a lean manufacturer is continuously improving. Most other books on lean management focus on technical methods and offer a picture of how a lean system should look like. Other books provide snapshots of companies before and after lean was implemented. This is the first book to provide technical descriptions of successful solutions and performance improvements. It's also the first book to go beyond snapshots and includes powerful first-hand accounts of the complete process of change; its impact on the entire organization; and the rewards and benefits of becoming lean. At the heart of Becoming Lean are the stories of American manufacturers that have successfully implemented lean methods. The writers offer personalized accounts of their organization's lean transformation. You have a unique opportunity to go inside the implementation process and see what worked, what didn't, and why.

Download or read book Lean Product and Process Development 2nd Edition written by Allen C. Ward and published by Lean Enterprise Institute. This book was released on 2014-03-05 with total page 509 pages. Available in PDF, EPUB and Kindle. Book excerpt: "The P-51 Mustang—perhaps the finest piston engine fighter ever built—was designed and put into flight in just a few months. Specifications were finalized on March 15, 1940; the airfoil prototype was complete on September 9; and the aircraft made its maiden flight on October 26. Now that is a lean development process!" —Allen Ward and Durward Sobek, commenting on the development of the P-51 Mustang and its exemplary use of trade-off curves. Shingo Research and Professional Publication Award recipient, 2008 Despite attempts to interpret and apply lean product development techniques, companies still struggle with design quality problems, long lead times, and high development costs. To be successful, lean product development must go beyond techniques, technologies, conventional concurrent engineering methods, standardized engineering work, and heavyweight project managers. Allen Ward showed the way. In a truly groundbreaking first edition of Lean Product and Process Development, Ward delivered -- with passion and penetrating insights that cannot be found elsewhere -- a comprehensive view of lean principles for developing and sustaining product and process development. In the second edition, Durward Sobek, professor of Mechanical and Industrial Engineering at Montana State University—and one of Ward’s premier students—edits and reorganizes the original text to make it more accessible and actionable. This new edition builds on the first one by: Adding five in-depth and inspiring case studies. Including insightful new examples and illustrations. Updating concepts and tools based on recent developments in product development. Expanding the discussion around the critical concept of set-based concurrent engineering. Adding a more detailed table of contents and an index to make the book more accessible and user-friendly. The True Purpose of Product Development Ward’s core thesis is that the very aim of the product development process is to create profitable operational value streams, and that the key to doing so predictably, efficiently, and effectively is to create useable knowledge. Creating useable knowledge requires learning, so Ward also creates a basic learning model for development. But Ward not only describes the technical tools needed to make lean product and process development actually work. He also delineates the management system, management behaviors, and mental models needed. In this breakthrough text, Ward: Asks fundamental questions about the purpose and “value added” in product development so you gain a crystal clear understanding of essential issues. Shows you how to find the most common forms of “knowledge waste” that plagues product development. Identifies four “cornerstones” of lean product development gleaned from the practices of successful companies like Toyota and its partners, and explains how they differ from conventional practices. Gives you specific, practical recommendations for establishing your own lean development processes. Melds observations of effective teamwork from his military background, engineering fundamentals from his education and personal experience, design methodology from his research, and theories about management and learning from his study of history and experiences with customers. Changes your thinking forever about product development.

Download or read book How To Implement Lean Manufacturing written by Lonnie Wilson and published by McGraw Hill Professional. This book was released on 2009-07-06 with total page 335 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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

Download or read book The Power of Process written by Matthew Zayko and published by CRC Press. This book was released on 2021-10-28 with total page 253 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lean Process Creation teaches the specific frames—the 6CON model—to look through to properly design any new process while optimizing the value-creating resources. The framing is applicable to create any process that involves people, technology, or equipment—whether the application is in manufacturing, healthcare, services, retail, or other industries. If you have a process, this approach will help. The result is 30% to 50% improvement in first-time quality, customer lead time, capital efficiency, labor productivity, and floorspace that could add up to millions of dollars saved per year. More important, it will increase both employee and customer satisfaction. The book details a case study from a manufacturing standpoint, starting with a tangible example to reinforce the 6CON model. This is the first book written from this viewpoint—connecting a realistic transformation with the detailed technical challenges, as well as the engagement of the stakeholders, each with their own bias. Key points and must-do actions are sprinkled throughout the case study to reinforce learning from the specific to the general. In this study, an empowered working team is charged with developing a new production line for a critical new product. As the story unfolds, they create an improved process that saves $5.6 million (10x payback on upfront resource investment) over the short life cycle of the product, as well as other measurable benefits in quality, ergonomics, and delivery. To an even greater benefit, they establish a new way of working that can be applied to all future process creation activities. Some organizations have tried their version of Lean process design following a formula or cookie-cutter approach. But true Lean process design goes well beyond forcing concepts and slogans into every situation. It is purposeful, scientific, and adaptable because every situation starts with a unique current state. In addition, Lean process design must include both the technical and social aspects, as they are essential to sustaining and improving any system. Observing the recurring problem of reworking processes that were newly launched brought the authors to the conclusion that a practical book focused on introducing the critical frames of Lean process creation was needed. This book enables readers to consider the details within each frame that must be addressed to create a Lean process. No slogans, no absolutes. Real thinking is required. This type of thinking is best learned from an example, so the authors provide this case study to demonstrate the thinking that should be applied to any process. High volume or low, simple or complex mix, manufacturing or service/transactional—the framing and thinking works. Along with the thinking, readers are enabled to derive their own future states. This is demonstrated in the story that surrounds the case study.

Download or read book Lean Manufacturing in the Developing World written by Jorge Luis García-Alcaraz and published by Springer Science & Business Media. This book was released on 2014-03-27 with total page 582 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents some definitions and concepts applied in Latin America on lean manufacturing (LM), the LM tools most widely used and human and cultural aspects that most matter in this field. The book contains a total of 14 tools used and reported by authors from different countries in Latin America, with definition, timeline with related research, benefits that have been reported in literature and case studies implemented in Latin American companies. Finally, the book presents a list of softwares available to facilitate the tools' implementation, monitoring and improvement.

Download or read book Lean Manufacturing written by Francisco J. G. Silva and published by . This book was released on 2019 with total page 466 pages. Available in PDF, EPUB and Kindle. Book excerpt: The paradigm of manufacturing is undergoing a major evolution throughout the world. The use of computers, the Internet and new challenges related to the Industry 4.0 have changed the way we engineer and manufacture products. Improving production with Lean Thinking is an evolution of a traditional approach in order to improve its processes to remain competitive in the global market. Lean Manufacturing is a multidimensional approach that embraces a wide variety of management practices in a unified system. These practices contain, quality systems, team work, and supplier management, among others. Nowadays, other practices have been adopted such as human factors and ergonomics. This book presents contributions of Lean Manufacturing applications in the world development and is intended to provide a comprehensive view of issues related to this area, with a specific focus on lean engineering principles; it is full of practical production examples of how Lean Thinking can be applied effectively to production systems. This work was conceptualized for an audience of graduate students mainly; however, it can also be consulted by engineers and company managers who seek state-of-the-art applications on Lean Manufacturing within a wide diversity of scenarios and conditions. The book, organized into 17 chapters, is intended to be an excellent source for dissemination of applied researches, lean concepts, and practices that have been successfully applied in the developing world domain. The book is also an excellent example of academy purpose with collaboration between different institutions from different countries that provide a global approach. Maria João Viamonte, PhD ISEP's President

Download or read book Handbook of Lean Manufacturing in the Food Industry written by Michael Dudbridge and published by John Wiley & Sons. This book was released on 2011-02-02 with total page 238 pages. Available in PDF, EPUB and Kindle. Book excerpt: The principles of lean manufacturing – increasing efficiency, reducing waste, lowering costs and improving control – may be applied to any industry. However, the food industry is unique, and creates unique demands. The political, social and economic importance of food is unrivalled by any other form of produce, as is the scrutiny to which the manufacture of food is subjected. For the food industry, lean manufacturing is not simply a cost-saving strategy, but is directly linked to issues of sustainability, the environment, ethics and public accountability. Handbook of Lean Manufacturing in the Food Industry is a major new source of information and ideas for those working in food manufacturing. Offering a fresh and modern perspective on best practice, it points the way to fewer breakdowns, reduced quality faults, improved teamwork and increased profits. With a focus on operations management and new process development, the book is accessible and easy to read, and is complemented by a wealth of practical examples drawn from industry. The author’s conversational style and questioning approach will be invaluable to food manufacturers who are seeking solutions to fundamental issues. The book is directed at those who are working in food manufacturing or the wider food industry, particularly factory operations managers and training teams who are looking for resources to help with lean manufacturing implementations. Others in the supply chain, from producers to retailers, will also find it invaluable. The book is a clear and timely introduction for students and lecturers in food science and technology who want to access the reality of lean manufacturing as well as the theory.