Download or read book Quality Improvement Inventory Management Lead Time Reduction and Production Scheduling in High mix Manufacturing Environments written by Sean Michael Daigle and published by . This book was released on 2017 with total page 97 pages. Available in PDF, EPUB and Kindle. Book excerpt: This thesis is a compilation of the analysis and recommendations gathered from two industry projects conducted at Applied Materials Varian Division in Gloucester, MA and at the MIT Lincoln Laboratory in Lexington, MA. This thesis addresses the improvement of a quality metric used at Applied Materials through the means of material shortage reduction and lead time reduction of system sub-assemblies. Manufacturing quality was found to be impacted by material shortages across the facility and capacity constraints in an area of the facility that manufactures equipment subassemblies. Implementing a new inventory policy would result in an expected 74% to 80% reduction in material shortage occurrences. The capacity increase recommended in this thesis would reduce average lead time for sub-assemblies from about 5-6 days to under 2 days. At the MIT Lincoln Lab, this thesis addresses a possible approach to improving the accuracy of production scheduling and delivery date quotes through the use of job shop scheduling software and historical data analysis. The recommended fabrication request delivery date prediction process involves using a scheduling software to find the optimal delivery date for a job, and then adding a Shop Capacity Buffer time that is calculated using historical data on schedule delays. Schedule delays can be caused by a variety of random events that occur in machine shops, such as machine failures or operators falling ill. By selecting a Shop Capacity Buffer of 90%, a 90% on-time completion rate should be observed. This new method would achieve improved results from the 75% on-time completion rate at present. The final recommendation is a policy change that aims to characterize sources of delay and accurately compensate for the delay using the Shop Capacity Buffer in the delivery date quote process..
Download or read book Made to Order Lean written by Greg Lane and published by CRC Press. This book was released on 2020-03-09 with total page 276 pages. Available in PDF, EPUB and Kindle. Book excerpt: Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs. About the author: Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS. He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales. Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: [email protected]
Download or read book High mix Low volume Manufacturing written by R. Michael Mahoney and published by Prentice Hall. This book was released on 1997 with total page 246 pages. Available in PDF, EPUB and Kindle. Book excerpt: Many of the problems manufacturers face seem to defy intuitive solutions . . . and are full of uncertainty and risk. But every situation--no matter how tentative or unsettling it seems--can be logically analyzed and systematically mapped out. "High-Mix, Low-Volume Manufacturing" covers the entire spectrum of manufacturing-related topics, from competitive strategies through performance measurements. Although there is a special focus on high-mix, low-volume manufacturing, there is much useful and valuable information for people in all other types of manufacturing. This book is a thorough reference for practitioners and academics interested in how manufacturing should and can be run. "High-Mix, Low-Volume Manufacturing" is a groundbreaking work, integrating ideas from many sources. In this book, manufacturing fundamentals are re-examined in a way that often gets overlooked by corporate strategists. This book is a comprehensive, practical, and detailed educational reference covering "global" concepts through "tactical" ideas in a clear and concise manner. The goal of this book is to develop the manufacturing core competencies required to obtain a competitive advantage. This book has both an immediate and long-term payoff.
Download or read book Lean Manufacturing System Design and Value Stream Management in a High mix Low volume Environment written by Matthew David Gates and published by . This book was released on 2004 with total page 156 pages. Available in PDF, EPUB and Kindle. Book excerpt: Value Stream Mapping is a powerful tool for identifying sources of waste and for creating the vision for the future state of a production system. As a management tool, however, it lacks in specific focus of roles, responsibilities, and actions required to achieve the future state vision. The limitations become more evident and the problems of execution become exacerbated when multiple value stream projects are launched with limited human resources available. This thesis describes a set of management tools to complement Value Stream Mapping. The tools are expected to improve management visibility and accountability. The design of a lean production system is also proposed in this thesis. The lean production system includes a newly designed layout for the manufacturing cell as well as the "operating system" for the cell. The layout is based on the principles of cellular manufacturing in order to promote flow and improve quality. The operating system includes such things as production batch sizes, product routings, and strategic inventory locations. Based on the future state value stream map and supported by a discrete-event simulation, the new operating system is designed to align the lean strategy with the technical capabilities of the manufacturing line. As confirmed by the simulation, implementation of the new production system is expected to reduce lead time for the cell by 2/3, realize a corresponding one-time reduction in inventory of $350,000, and increase on-time delivery of the cell to over 97%. In total, the project has a three-year net present value exceeding a quarter of a million dollars.
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 LEAN Supply Chain Planning written by Josef Packowski and published by CRC Press. This book was released on 2013-11-26 with total page 496 pages. Available in PDF, EPUB and Kindle. Book excerpt: Delivering excellent service to all customers is the key imperative for many sustainable businesses. So why do so many supply chains struggle to fulfill customer requirements at competitive costs? The answer is simple: traditional supply chain planning, which was tailored to a predominantly stable and predictable business environment, cannot handle the new challenges in the world of variability, uncertainty, complexity, and ambiguity—the VUCA world. Companies can either accept the drawbacks that often result in high inventories, poor asset utilization, and unsatisfactory customer service or, they can change their view of the fundamental approach to supply chain management. LEAN Supply Chain Planning: The New Supply Chain Management Paradigm for Process Industries to Master Today’s VUCA World introduces a new paradigm and a new approach to managing variability, uncertainty, and complexity in today’s planning processes and systems. Introducing a cutting-edge supply chain management concept that addresses current problems in the process industry's supply chains, the book presents powerful methods developed by leading research institutes, process industry champions, and supply chain experts. It explains how readers can change their approach to the fundamental planning paradigms in a manner that will help their organizations achieve higher levels of responsiveness, improved levels of customer service, and substantial increases in cost-efficiencies. This holistic practitioner’s guide describes how to establish the right accountabilities for performance management and also provides a set of meaningful metrics to help measure your progress. Supplying detailed guidelines for transforming your supply chain, it includes first-hand reports of leading organizations that have already adopted some of the facets of this paradigm and used the relevant instruments to achieve unprecedented improvements to customer service, supply chain agility, and overall equipment effectiveness.
Download or read book Competitive Manufacturing Management written by John M. Nicholas and published by McGraw-Hill/Irwin. This book was released on 1998 with total page 872 pages. Available in PDF, EPUB and Kindle. Book excerpt: Race without a finish line - Fundamentals of continuous improvement - JIT : value added and waste elimination - TQM : customer-focused quality - Small-lot production - Setup-time reduction - Maintaining and improving equipment - Pull production systems - Focused factories and group technology - Workcells and cellular manufacturing - Standard operations - Quality of design - Quality inspection and statistical sampling - Statistical process control - Systems for eliminating defects - Scheduling for smooth flow - Synchronizing and balancing processes - Planning and control in pull production - Managing the supply chain - Activity-based costing - Performance measurement : making bean counting relevant.
Download or read book Speed to Market written by Vincent Bozzone and published by AMACOM/American Management Association. This book was released on 2001 with total page 268 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lean manufacturing is the single most effective way to increase sales, cut costs, improve margins, and secure the future of a business. The problem is that the principles and philosophies of lean manufacturing are geared strictly to mass production operations and can be ineffective, even detrimental, for smaller job shops and make-to-order businesses. Now, Speed to Market delivers a proven approach for smaller suppliers who want to successfully cut their lead time and trigger profitable growth. Completely updated and expanded, the book explains how to: * Apply the principles of pull, flow, and the elimination of waste to every area of the company, at every stage from quotes to cash* Implement a continuous improvement process while sidestepping the typical implementation pitfalls* Ease scheduling problems* Improve performance and profitability using the book's practical concepts, process analysis tools, and perspective-enhancing techniques and much more
Download or read book Production Planning and Scheduling for Lot Processing written by Larysa Burtseva and published by Cambridge Scholars Publishing. This book was released on 2022-07-29 with total page 429 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is dedicated to questions of production planning and scheduling activities both in general and in semiconductor manufacturing environments, which have the characteristics of high volume and high mixture. It explores topics such as shop models, work-in-process management, the treatment of setup times, basic techniques of lot batching and splitting, lot sizing and group technology approaches, as well as rescheduling questions. A number of directions for further research is suggested in the book, and a broad collection of references is provided.
Download or read book Lean Production for the Small Company written by Mike Elbert and published by CRC Press. This book was released on 2012-08-07 with total page 299 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 describes problems and pitfalls along with time-tested solutions. Explaining how to incorporate existing systems into a Lean strategy, the book starts with the fundamentals and builds on them to describe the full range of tools and processes needed to implement Lean. It outlines how to design factories for Lean manufacturing and demonstrates how to remove variations within business and manufacturing processes to achieve a smooth continuous flow of product that delivers your product on time to customers. The tools, methods, and ideals discussed are applicable in any industry and all parts of your business—from manufacturing and sales to human resources. The text unveils new methods and tools that can help you reduce inventory, improve inventory turns, and facilitate raw material flow through the factory. It details how to use customer order demands to schedule the production floor, rather than using estimated production schedules. It also considers the accounting process and explains how to improve your cash-to-cash cycle time. Drawing on the author’s decades of experience transforming high-mix plants to Lean, the text brings together coverage of the tools and processes that have made Toyota so successful. All the chapters in this book, when implemented, will result in a culture change that will transform your company into a learning organization that continuously eliminates waste and improves its processes.
Download or read book Equalized Synchronized Production written by Toshiki Naruse and published by CRC Press. This book was released on 2003-02-16 with total page 320 pages. Available in PDF, EPUB and Kindle. Book excerpt: Beyond JIT - Lean Improvement for Supplier Companies! ESP is a production management and manufacturing improvement system targeted for supplier companies or any companies that deal with a variety of products as well as multiple customers. ESP enables suppliers to meet the requirements of their buyers' Just-In-Time (JIT) ordering systems through wide-variety, small-lot production, while also making their own production activities as efficient as possible. ESP complements each company's own production management functions, particularly the production scheduling and purchasing functions, in the way that best suits each individual business. By adopting ESP, your company will be able to meet its customers' needs Just-in-Time while growing into a powerful new organization operating according to its own production system. Features of Equalized and Synchronized Production include: Coverage of the complete production scheduling and management system for supplier organizations Case studies featuring ESP implementation by a variety of manufacturers Guidance on when and where the ESP system is more effective than JIT Comprehensive and practical "how-to" instruction on ESP implementation
Download or read book Manufacturing and Supply Systems Management written by B. Wu and published by Springer Science & Business Media. This book was released on 2012-12-06 with total page 542 pages. Available in PDF, EPUB and Kindle. Book excerpt: In order to compete in an increasingly demanding market, many manufacturing companies have to redesign or restructure their manufacturing systems so that a set of coherent manufacturing strategies can be supported. So this book aims to provide a comprehensive treatment of manufacturing strategy analysis (MSA) and manufacturing systems design (MSD). The strategic concerns of manufacturing are linked to subsequent manufacturing systems design activities through the use of an effective MSA/MSD interface. Topics include: A structured approach to formulating manufacturing strategies; A set of linking processes to translate MSA concerns into relevant MSD action plans; Case studies. This book is intended to help graduates and industry-based professionals to make more informed decisions when working on system-design or redesign projects.
Download or read book Lean Supply Chain Management Essentials written by Bill Kerber and published by CRC Press. This book was released on 2011-06-27 with total page 278 pages. Available in PDF, EPUB and Kindle. Book excerpt: Presenting an alternate approach to supply chain management, Lean Supply Chain Management Essentials: A Framework for Materials Managers explains why the traditional materials planning environment, typically embodied by an Enterprise Resource Planning (ERP) system, is an ineffective support system for a company that wants to adopt Lean practices. It begins by defining supply chain management basics, including roles, objectives, and responsibilities from a traditional framework. Next, it describes Lean basics and explores the conflicts between Lean and the traditional framework. The book focuses on the materials management aspects of Lean, such as leveling work into the value stream, heijunka scheduling, standard work, and the concept of intervals, including Every Part Every Interval (EPEI). By combining traditional materials management tools, such as Sales and Operations Planning (S&OP), with Lean manufacturing approaches and applying them to different manufacturing environments, the authors clarify the logic behind why you are doing what you’re doing with Lean components and how they fit together as a system. Specifically, they explain how to: Determine which leveling strategy to use to smooth production Calculate interval to determine lot sizes in various production environments Apply Lean to purchasing, warehouse, and logistics areas Use your value stream map for green initiatives and risk management Replace capacity planning and shop floor control with visual factory, operator balance charts, EPEI, and plan for every part Illustrating why balancing demand and capacity is better than trying to balance supply and demand, the book includes a definitive chart that matches Lean tools to the planning and control charts that have served as the model for ERP systems. It integrates the principles learned from Toyota’s fifty-plus-year journey with Lean principles to provide the up-to-date understanding required to approach the application of Lean to your supply chain with a methodology that allows for experimentation, learning, and continuous improvement.
Download or read book World Class Production and Inventory Management written by Darryl V. Landvater and published by John Wiley & Sons. This book was released on 1997-07-31 with total page 314 pages. Available in PDF, EPUB and Kindle. Book excerpt: Eine Pflichtlektüre für jeden, der für Distributions-, Produktions- und Lagerhaltungsmanagement verantwortlich ist! "Heiße Themen" wie Just-in-time-Planung, Master Production Scheduling und Kapazitätsplanung werden ausführlich diskutiert.
Download or read book Lean Business Systems and Beyond written by Tomasz Koch and published by Springer Science & Business Media. This book was released on 2008-01-28 with total page 485 pages. Available in PDF, EPUB and Kindle. Book excerpt: Lean Manufacturing has proved to be one of the most successful and most powerful production business systems over the last decades. Its application enabled many companies to make a big leap towards better utilization of resources and thus provide better service to the customers through faster response, higher quality and lowered costs. Lean is often described as “eyes for flow and eyes for muda” philosophy. It simply means that value is created only when all the resources flow through the system. If the flow is stopped no value but only costs and time are added, which is muda (Jap. waste). Since the philosophy was born at the Toyota many solutions were tailored for the high volume environment. But in turbulent, fast-changing market environment and progressing globalization, customers tend to require more customization, lower volumes and higher variety at much less cost and of better quality. This calls for adaptation of existing lean techniques and exploration of the new waste-free solutions that go far beyond manufacturing. This book brings together the opinions of a number of leading academics and researchers from around the world responding to those emerging needs. They tried to find answer to the question how to move forward from “Spaghetti World” of supply, production, distribution, sales, administration, product development, logistics, accounting, etc. Through individual chapters in this book authors present their views, approaches, concepts and developed tools. The reader will learn the key issues currently being addressed in production management research and practice throughout the world.
Download or read book Finite Capacity Scheduling written by Bill Kirchmier and published by Ippsa. This book was released on 2013-12 with total page 234 pages. Available in PDF, EPUB and Kindle. Book excerpt: Finite Capacity Scheduling: Optimizing a Constrained Supply Chain introduces the reader to a critical tool for driving enterprise and supply chain competitive excellence. It teaches the reader how to beat the competition by: . Reducing in-stock inventory and inventory cost . Reducing logistics costs . Increasing on time delivery which increases customer satisfaction . Reducing stock-outs . Improved Supply Chain and Enterprise scheduling and load balancing This book's focus is on scheduling and coordinating demand for Material, Labor, Machine resources and balancing them with available Capacity. Finite Capacity Scheduling identifies an executable balance between resource demand and resource availability; all while coordinating shipments to Supply Chain management systems. FCS schedules everything from HMLV systems and components to HVLM production items; all this while interfacing with enterprise-wide ERP systems. This book: . Shows how FCS optimizes resource scheduling options; including material, equipment, personnel, tools, etc.; anything that creates a constraint on throughput. . Describes how to seamlessly integrate FCS and ERP in a single database . Explains how FCS effectively coordinates material and capacity resources . Shows how FCS delivers feasible Finite Scheduling for Material and Capacity . Schedules work based on actual material and capacity availability . Supports interfacing ERP production with Supply Chain Management systems. . Explains how and why FCS offers feasibility and flexibility The book is a comprehensive guide to understanding, implementing and managing material and capacity resources for the full Supply Chain Management Spectrum of production scheduling applications including complex High Mix Low Volume (HMLV) and simplistic High Volume Low Mix (HVLM) production environments.
Download or read book Master Scheduling written by John F. Proud and published by John Wiley & Sons. This book was released on 2013-08-12 with total page 688 pages. Available in PDF, EPUB and Kindle. Book excerpt: Master scheduling is an essential planning tool that helps manufacturers synchronize their production cycle with actual market demand. The third edition of this easy-to-follow handbook helps you understand the basic and more advanced concepts of master scheduling, from implementation to capacity planning to final assembly techniques. Packed with handy checklists and examples, Master Scheduling, Third Edition delivers guidelines and techniques for a world-class master schedule.
