Download or read book Applying Lean Manufacturing Concepts to a High mix Low volume Make to Order Environment written by Andrew Rodriguez (M.B.A.) and published by . This book was released on 2021 with total page 86 pages. Available in PDF, EPUB and Kindle. Book excerpt: Despite research documenting the operational benefits achieved by reducing the number of product offerings, manufacturing businesses frequently serve markets in which customers demand a large variety of products with options across multiple features at irregular intervals. To meet customer requirements across a range of possible demand, businesses manage the high mix and low volume by choosing to make-to-order instead of make-to-stock. While principles of Lean Manufacturing have been recognized as enablers of operational excellence in high volume production operations, questions remain about the applicability of the concepts in high-mix, low-volume, make-to-order environments. This project explores the applicability of Lean concepts within this manufacturing environment at PSI Control Solutions (PSI), a mid-sized business assembling electrical distribution and control products for industrial consumers. To stay competitive, the business must provide high quality, cost competitive products that meet customer specifications with minimal lead times. Within this organization, the primary research areas for applying Lean concepts were component replenishment policy and production process improvement. After a production cell applied the methods of eliminating waste, mistake proofing, and pull, it increased the percent of sales delivered on time to the customer desired date from 85.7% to 100% over subsequent 3 month periods and improved product first pass-yield from 87.9% to 93.1% over 6 month periods.

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 Job Shop Lean written by Shahrukh A. Irani and published by CRC Press. This book was released on 2020-05-04 with total page 692 pages. Available in PDF, EPUB and Kindle. Book excerpt: In the 1950’s, the design and implementation of the Toyota Production System (TPS) within Toyota had begun. In the 1960’s, Group Technology (GT) and Cellular Manufacturing (CM) were used by Serck Audco Valves, a high-mix low-volume (HMLV) manufacturer in the United Kingdom, to guide enterprise-wide transformation. In 1996, the publication of the book Lean Thinking introduced the entire world to Lean. Job Shop Lean integrates Lean with GT and CM by using the five Principles of Lean to guide its implementation: (1) identify value, (2) map the value stream, (3) create flow, (4) establish pull, and (5) seek perfection. Unfortunately, the tools typically used to implement the Principles of Lean are incapable of solving the three Industrial Engineering problems that HMLV manufacturers face when implementing Lean: (1) finding the product families in a product mix with hundreds of different products, (2) designing a flexible factory layout that "fits" hundreds of different product routings, and (3) scheduling a multi-product multi-machine production system subject to finite capacity constraints. Based on the Author’s 20+ years of learning, teaching, researching, and implementing Job Shop Lean since 1999, this book Describes the concepts, tools, software, implementation methodology, and barriers to successful implementation of Lean in HMLV production systems Utilizes Production Flow Analysis instead of Value Stream Mapping to eliminate waste in different levels of any HMLV manufacturing enterprise Solves the three Industrial Engineering problems that were mentioned earlier using software like PFAST (Production Flow Analysis and Simplification Toolkit), Sgetti and Schedlyzer Explains how the one-at-a-time implementation of manufacturing cells constitutes a long-term strategy for Continuous Improvement Explains how product families and manufacturing cells are the basis for implementing flexible automation, machine monitoring, virtual cells, Manufacturing Execution Systems, and other elements of Industry 4.0 Teaches a new method, Value Network Mapping, to visualize large multi-product multi-machine production systems whose Value Streams share many processes Includes real success stories of Job Shop Lean implementation in a variety of production systems such as a forge shop, a machine shop, a fabrication facility and a shipping department Encourages any HMLV manufacturer planning to implement Job Shop Lean to leverage the co-curricular and extracurricular programs of an Industrial Engineering department

Download or read book The Application of Lean Manufacturing Principles in a High Mix Low Volume Environment written by Amber Nicole Dudley and published by . This book was released on 2005 with total page 71 pages. Available in PDF, EPUB and Kindle. Book excerpt: This thesis studies the opportunities for the application of lean manufacturing tools in a high- mix, low-volume traditional manufacturing factory floor setting. Value stream mapping and associated analytical tools are used to explore the opportunities to streamline the flow of products on the floor with a focus on reducing inventory and improving quality. To complement the analysis, this thesis also examines the impact of improved floor employee involvement. It considers several aspects including the increased empowerment of the direct labor staff, stronger team participation, and a greater focus on solutions specifically tailored to area. Based on the results of the research, the recommendation is an increased focus on developing team skills and empowerment, specifically within the direct labor staff.

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 Mr Lean Buys and Transforms a Manufacturing Company written by Greg Lane and published by Productivity Press. This book was released on 2009-12-17 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This is the true story of how, armed with only Lean improvement methodologies, a specially trained Toyota Lean expert purchased a business he knew nothing about, applied Lean techniques, and succeeded in doubling sales and increasing profitability, before he finally sold the thriving business. With humility and humor, the author recounts his successes and failures, introduces his key employees and their struggles with change, and provides motivation and simple ideas for all readers looking to improve their businesses. He captures key points highlighted in text boxes and includes illustrative photos and examples of Lean tools at work. This story dispels the fallacy that Lean management does not achieve excellent results in high variation companies and job shops. Toyota’s OSKKK methodology is introduced to understand processes and guide a Lean transformation on the shop floor and in the office.

Download or read book Applicability of Lean Manufacturing and Quick Response Manufacturing in a High mix Low volume Environment written by Matthew John Joing and published by . This book was released on 2004 with total page 66 pages. Available in PDF, EPUB and Kindle. Book excerpt: As today's manufacturers face increasing pressure to improve costs and compete globally, many are turning to the philosophy of Lean Manufacturing as exemplified by the Toyota Production System. Lean is most successful when production is characterized by a few high-volume products, but may not be the answer as the production mix increases and volume decreases. This thesis focuses on this high-mix, low-volume type of production in addition to two other key production system characteristics: demand variability and degree of customization. A manufacturer's position along these four characteristics is very important to the applicability of Lean theory. The alternative philosophy of Quick Response Manufacturing (QRM) is compared to Lean and shown to offer a better fit in some cases. One such case where Lean does not fit neatly is circuit card assembly at Raytheon Systems Limited in Glenrothes, Scotland, where the author conducted his six-month LFM internship. Five steps towards manufacturing improvement are focused on in this thesis: choosing metrics, reorganizing the factory, selecting lot sizes, implementing a production control strategy, and deciding on a material presentation method. The recommended steps to improve circuit card assembly include ideas from both Lean and QRM. This mix of ideas was implemented at Raytheon before the end of the internship and resulted in marked improvement. On-time delivery and customer satisfaction dramatically improved while lead times and inventories dropped significantly. Using Lean Manufacturing as the sole guideline for improvement was not appropriate for this particular manufacturing system. The final takeaway from the internship and thesis is that there is no one-size-fits-all manufacturing philosophy.

Download or read book Making materials flow written by Rick Harris and published by Lean Enterprise Institute. This book was released on 2003 with total page 107 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Lean Manufacturing in Build to Order Complex and Variable Environments written by Jorge Larco and published by . This book was released on 2015-10-05 with total page 192 pages. Available in PDF, EPUB and Kindle. Book excerpt: A business that can provide exactly what its customers want at a competitive price, and do so when its customers want delivery, will have an insurmountable advantage over competition that cannot. That's why from oil rigs to trucks customized for specific purposes, from large scale HVAC systems and ship engines to houses and airplanes, this book will create a new playing field for leaders of companies who wish to offer customers complex products that are built to order. The authors show and tell how it is not necessary to move production offshore to achieve lower costs and at the same time produce products customized for specific needs. And they explain how quality and speed of delivery will simultaneously be enhanced by using lean manufacturing techniques. No wonder this book a must read for anyone involved in manufacturing in today.

Download or read book Lean Management Beyond Manufacturing written by Sanjay Bhasin and published by Springer. This book was released on 2015-04-20 with total page 300 pages. Available in PDF, EPUB and Kindle. Book excerpt: Exploring Lean manufacturing in a holistic manner, this book helps organizations to implement Lean principles successfully by offering theoretical, empirical and practical knowledge. It empirically demonstrates how a successful Lean initiative can improve organizational efficiency, and incorporates valuable primary research to substantiate findings. It argues that Lean principles need to be applied throughout the value chain in order to be successful , and suggests that these tools need to be aligned with culture and change management. Chapters examine issues including Lean cultures, impediments to Lean, Lean and performance measurement, and the impact of Lean. Viewing Lean as a never-ending journey, this book provides a valuable resource to practising Lean managers, and specialist researchers and students, and also offers an important reference for organizations embarking on their Lean voyage.

Download or read book The Lean Manager written by Freddy Ballé and published by Lean Enterprise Institute. This book was released on 2011-09-15 with total page 473 pages. Available in PDF, EPUB and Kindle. Book excerpt: In this groundbreaking sequel to The Gold Mine, authors Michael and Freddy Ballé present a compelling story that teaches readers the most important lean lesson of all: how to transform themselves and their workers through the discipline of learning the lean system. The Lean Manager: A Novel of Lean Transformation reveals how individuals can go beyond the short-term gains from tools, and realize a deeper, sustainable path of improvement. Full of human moments that capture the excitement and drama of lean implementation, as well as clear explanations of how tools and systems go hand-in-hand, this book will teach and inspire every person working to make lean a reality in their organization today. This book will help you learn both the how of doing lean, as well as the why behind the tools, enabling you to become lean. Lean is the most important business model for competitive success today. Yet companies still struggle to sustain enduring and deep-rooted business success from their lean implementation efforts. The most important problem for these companies is becoming lean: how can they advance beyond realizing isolated gains from deploying lean tools, to fundamentally changing how they operate, think, and learn? In other words, how can companies learn to go beyond lean turnaround to achieve lean transformation? The Lean Manager: A Novel of Lean Transformation, by lean experts Michael and Freddy Ballé, addresses this critical problem. As we move from what Jim Womack, author, lean management authority, and LEI founder, calls “the era of lean tools to the era of lean management,” The Lean Manager gives companies a definitive guide for sustaining their ability to learn and improve operations and financial performance, while continually developing people. “The only way to become and stay lean is to produce lean managers,” says Womack. “Every isolated effort will recede—or fail—unless companies learn to use the lean process as a way of developing individual problem-solvers with the ownership, initiative, and know-how to solve problems, learn, and ultimately coach new individuals in this discipline. That’s why this book matters so much.” The Lean Manager, the sequel to the Ballé’s international bestselling business novel The Gold Mine, tells the compelling story of plant manager Andrew Ward as he goes through the challenging but rewarding journey to becoming a lean manager. Under the guidance of Phil Jenkinson (whose own lean journey was at the core of The Gold Mine), Ward learns to use a deep understanding of lean tools, as well as a technical know-how of his plant’s operations, to foster a lean attitude that sustains continuous improvement. Where The Gold Mine shows you how to introduce a complete lean system, The Lean Manager demonstrates how to sustain it. Ward moves beyond fluency with tools to changing his behavior as a manager and leader. He shifts from giving orders and answers to asking the right questions so people identify and address problems. He learns how to use tools to unleash the creativity and motivation of people, so they learn how to solve problems as well as coach and teach others to solve problems. Ward learns how to create lean managers. “I am excited and have hopes that this book will enlighten readers about what it really means to live a business transformation that puts customers first and does this through developing people,” said Jeffrey Liker, author of The Toyota Way and professor of Industrial and Operations Engineering at the University of Michigan. “People who do the work have to improve the work. There are tools, but they are not tools for ‘improving the process.’ They are tools for making problems visible and for helping people think about how to solve those problems.”

Download or read book The Goal written by Eliyahu M. Goldratt and published by Routledge. This book was released on 2016-08-12 with total page 471 pages. Available in PDF, EPUB and Kindle. Book excerpt: Alex Rogo is a harried plant manager working ever more desperately to try and improve performance. His factory is rapidly heading for disaster. So is his marriage. He has ninety days to save his plant - or it will be closed by corporate HQ, with hundreds of job losses. It takes a chance meeting with a colleague from student days - Jonah - to help him break out of conventional ways of thinking to see what needs to be done. Described by Fortune as a 'guru to industry' and by Businessweek as a 'genius', Eliyahu M. Goldratt was an internationally recognized leader in the development of new business management concepts and systems. This 20th anniversary edition includes a series of detailed case study interviews by David Whitford, Editor at Large, Fortune Small Business, which explore how organizations around the world have been transformed by Eli Goldratt's ideas. The story of Alex's fight to save his plant contains a serious message for all managers in industry and explains the ideas which underline the Theory of Constraints (TOC) developed by Eli Goldratt. Written in a fast-paced thriller style, The Goal is the gripping novel which is transforming management thinking throughout the Western world. It is a book to recommend to your friends in industry - even to your bosses - but not to your competitors!

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 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 Creating Mixed Model Value Streams written by Kevin J. Duggan and published by CRC Press. This book was released on 2018-02-05 with total page 258 pages. Available in PDF, EPUB and Kindle. Book excerpt: Following in the footsteps of its bestselling predecessor, Kevin J. Duggan, an executive mentor and recognized authority on Lean and Operational Excellence, draws on more than 10 years of experience and learning to provide Creating Mixed Model Value Streams, Second Edition. This second edition takes a step-by-step approach to implementing Lean in c

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 Design for Manufacturability written by David M. Anderson and published by CRC Press. This book was released on 2014-02-04 with total page 472 pages. Available in PDF, EPUB and Kindle. Book excerpt: Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production shows how to use concurrent engineering teams to design products for all aspects of manufacturing with the lowest cost, the highest quality, and the quickest time to stable production. Extending the concepts of desi