Lean Manufacturing Tools, Techniques, and How To Use Them

Lean manufacturing, sản xuất

Lean Manufacturing Tools, Techniques, and How T o Use Them Applying Manufacturing Execution Systems by Michael McClellan Back to Basics: Your Guide to Manufacturing Excellence By Steven A. Melnyk R.T. “Chris” Christensen Enterprise Resources Planning and Beyond: Integrating Your Entire Organization by Gary A. Langenwalter ERP: Tools, Techniques, and Applications for Integrating the Supply Chain by Carol A. Ptak with Eli Schragenheim Integral Logistics Management: Planning and Control of Comprehensive Business Processes by Paul Schönsleben Inventory Classification Innovation: Paving the Way for Electronic Commerce and Vendor Managed Inventory by Russell G. Broeckelmann Lean Manufacturing: Tools, Techniques, and How To Use Them by William M. Feld Macrologistics Management: A Catalyst for Organizational Change by Martin Stein and Frank Voehl Restructuring the Manufacturing Process: Applying the Matrix Method by Gideon Halevi Supply Chain Management: The Basics and Beyond by William C. Copacino The St. Lucie Press/APICS Series on Resource Management Titles in the Series The St. Lucie Press/APICS Series on Resource Management Alexandria, Virginia St. Lucie Press Boca Raton • London New York • Washington, D.C. by WILLIAM M. FELD Lean Manufacturing Tools, Techniques, and How To Use Them This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. The consent of St. Lucie Press does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from St. Lucie Press for such copying. Direct all inquiries to St. Lucie Press, 2000 N.W. Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. © 2001 by William M. Feld No claim to original U.S. Government works International Standard Book Number 1-57444-297-X Library of Congress Card Number 00-059163 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper Library of Congress Cataloging-in-Publication Data ______________________________________________________________________ Feld, William M. Lean manufacturing : tools, techniques, and how to use them / by William M. Feld. p. cm. Includes bibliographical references (p. ) and index. ISBN 1-57444-297-X (alk. paper) 1. Production management. 2. Costs, industrial. 3. Production management — Case studies. I. Title. TS155 .F4985 2000 658.5—dc21 00-059163 Final Front Matter Page 4 Saturday, August 12, 2000 1:46 AM 5 Dedication This book is dedicated to my four sons — Benjamin, Nathan, Jacob, and Samuel. Thank you for never letting me forget that I am your dad. Final Front Matter Page 5 Saturday, August 12, 2000 1:46 AM Final Front Matter Page 6 Saturday, August 12, 2000 1:46 AM 7 Contents Part I. Description of Lean Manufacturing Chapter 1. Lean Manufacturing: A “Holistic” View . 3 Chapter 2. Lean Manufacturing Approach . 7 Part II. Five Primary Elements Chapter 3. Organization Element 23 Chapter 4. Metrics Element 35 Chapter 5. Logistics Element 45 Chapter 6. Manufacturing Flow Element 61 Chapter 7. Process Control Element 79 Chapter 8. Sustaining the Change 91 Part III. Putting It All Together Chapter 9. Setting the Stage 95 Chapter 10. How It Begins 99 Chapter 11. The Game Plan 101 Chapter 12. Lean Assessment . 105 Chapter 13. Current State Gap . 111 Chapter 14. Future State Design 119 Chapter 15. Deployment . 131 Chapter 16. The Results 139 Final Front Matter Page 7 Saturday, August 12, 2000 1:46 AM 8 Lean Manufacturing: Tools, Techniques, and How To Use Them Part IV. Case Studies Case Study A: Operations Redesign Program 143 Case Study B: Kaizen Event-Based Lean Program . 155 Case Study C: High-Volume-Focused Factory Project 165 Case Study D: Kaizen Event-Based Focused Factory Pilot . 175 Case Study E: Assembly Production Unit Project 185 Case Study F: High-Volume and Low-Volume Cell Project 195 Glossary 207 References . 219 Index 223 Final Front Matter Page 8 Saturday, August 12, 2000 1:46 AM 9 Preface This book was written in order to give the general manufacturing practitioner a reference guide by which to lead the successful design and deployment of a lean manufacturing program. It is for those individuals who have either tried a lean manufacturing implementation and received undesirable results or have been working at it a while and do not really know what to do next. Over the years, I have become more and more pragmatic in my approach to lean man- ufacturing. I am not a purist when it comes to methodology. In fact, in this book I am sharing with you information based on my own personal research, true-life experiences, and lessons learned through the implementation of lean principles within a number of companies. It is this broad-based experience that has allowed me to develop such a pragmatic approach. My experience has taught me that, although a specific philosophy may work well with one particular project or company, it may not work as well universally across other operations. The information, time frames, and methodologies contained within this book are geared primarily for operations that have 300 to 500 employees. The content was written for an audience operating at the level of plant manager, project manager, or manufacturing manager within a business, although most certainly schedulers, planners, industrial engineers, and first- line supervisors can also benefit from this material. The book provides tools and techniques that can be used for both high-volume/low-mix and low- volume/high-mix product environments. Although many of the techniques are designed for discrete unit manufacturing operations, those in the process industries could utilize many of the principles presented here, as well. I realize that there are some of you who operate within an environment that does not require you to justify your position on lean manufacturing every step of the way and that such an environment will accept the need for Final Front Matter Page 9 Saturday, August 12, 2000 1:46 AM [...]... are from being lean Facilities that are considered lean operate with far fewer resources as compared to those facilities that operate as mass producers: Lean production vs mass production: 1/2 the human effort in 7 Chapter 02 Page 8 Friday, August 11, 2000 11:03 PM 8 Lean Manufacturing: Tools, Techniques, and How To Use Them the factory, 1/2 the manufacturing space, 1/2 the investment tools, 1/2 the... executive management to report the findings and gain approval to move on to the next phase, that of documenting the Current State Gap (Figure 2.3) The Current State Gap provides the baseline measure of where the company is today In this phase, the team: Chapter 02 Page 12 Friday, August 11, 2000 11:03 PM 12 Lean Manufacturing: Tools, Techniques, and How To Use Them Lean Manufacturing and PVA Training Current... annual reports tells the story with surprising accuracy: inventory turnover (cost of sales divided by on-hand inventory) 3 Chapter 01 Page 4 Friday, August 11, 2000 11:00 PM 4 Lean Manufacturing: Tools, Techniques, and How To Use Them It happens that when a company manages its processes poorly, waste in the form of inventory piles up.”17 Not only are these lean principles interactive and co-dependent, but... knowing how to use them Willingness is the motivation to apply those skills to a particular situation.”3 Viewing lean manufacturing from a holistic perspective should be able to satisfy the need to have both ability and willingness Chapter 02 Page 7 Friday, August 11, 2000 11:03 PM 2 Lean Manufacturing Approach T he first step required on this journey toward creating a lean manufacturing environment is to. .. it stands today It will provide feedback regarding where we currently demonstrate capability, and it will reveal gaps between how things are being done today and what are considered to be sound lean practices To provide some level of insight into this gap, one need only to look at the landmark MIT study conducted by Womack, Jones, and Roos (see The Machine That Changed the World) to understand how far... Saturday, August 12, 2000 1:46 AM 10 Lean Manufacturing: Tools, Techniques, and How To Use Them lean management based on faith This book was not written for you This book was written for your colleagues — those who need to justify their position every step of the way and must constantly battle “hurdle management” to deploy their lean programs You know who you are and you know what I am talking about... understanding as to why we need to change, and we must determine why it is important that we make a change What are the business drivers that have caused this intrusion of lean manufacturing into our lives and why should we care to participate? Answers to these questions are required in order for people to become engaged in the change process How we handle the responses to these questions is critical to. .. has conducted nearly 30 years of research on teams, team dynamics, and developing insight into what makes successful teams work (see Belbin Associates’ Website: www.belbin.com) Chapter 02 Page 10 Friday, August 11, 2000 11:03 PM 10 Lean Manufacturing: Tools, Techniques, and How To Use Them In addition to the project charter and milestone plan, the following elements should also be considered as necessary... 16 Saturday, August 12, 2000 1:46 AM 16 Lean Manufacturing: Tools, Techniques, and How To Use Them Ⅲ Educational Opportunities — Held around the country, APICS’ International Conference and Exhibition, workshops, and symposia offer you numerous opportunities to learn from your peers and management experts Ⅲ Employment Referral Program — A cost-effective way to reach a targeted network of resource management... management protocol Once the team is up and operating, it is time to get down to business For the team, this means working their way through each of the lean road map phases The first phase, that of Lean Assessment (Figure 2.2), is used to determine how the operation stacks up area by area and product group by product group from a lean manufacturing perspective In this phase, the team tries to understand where . Lean Manufacturing Tools, Techniques, and How T o Use Them Applying Manufacturing Execution Systems by Michael McClellan Back to Basics:. William M. Lean manufacturing : tools, techniques, and how to use them / by William M. Feld. p. cm. Includes bibliographical references (p. ) and index.