Quick response manufacturing: a companywide approach to reducing lead times
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York, NY
Productivity Press
1998
|
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XXX, 544 S. Ill., graph. Darst. |
| ISBN: | 1563272016 |
Internformat
MARC
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Datensatz im Suchindex
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| adam_text | Contents
Publisher s Message xiii
Foreword xvii
Preface xxi
Acknowledgments xxv
Part One: A New Way of Thinking Stems from One Principle 1
Chapter One: QRM: Not Just Another Buzzword 3
How QRM Differs from Other Continuous Improvement
and Quality Programs 6
Implementing QRM: What Managers Believe 8
Perceptions of Implementing QRM in North American Companies 11
QRM Principles 17
Implementing QRM-The Prerequisites for Success 22
Improvement for the Entire Organization Comes from a
Single Theme 24
Chapter Two: Benefits of QRM 27
Benefits of Quick Response in Product Introduction 29
Benefits of Quick Response in Existing Production 30
Waste Due to Long Lead Times and Late Deliveries 34
Results of Quick Response Strategies 38
Benefits of Quick Response in Securing Orders 41
Benefits of QRM: Forewarned Is Forearmed 44
Chapter Three: The Response Time Spiral—Legacy of the
Scale and Cost Management Strategies 53
The Eras of Scale and Cost Strategies 54
The Response Time Spiral for Three Different Manufacturing
Environments 57
Other Policies That Promote the Response Time Spiral 67
Roots of the Response Time Spiral 69
Eliminating the Response Time Spiral 78
vii
viii Contents
Part Two: Rethinking Production and Materials Management 85
Chapter Four: Reorganizing Production 87
Seven Key Principles for Restructuring Your Company 88
The Manufacturing Cell-Creating the Product-Focused
Organization 89
Staffing and Training Cell Workers 96
Planning, Scheduling, and Control with Cells 100
Cells Foster Continuous Improvement 102
Chapter Five: Structured Methodology for Implementing Cellular
Manufacturing 107
Seven Steps to Successfully Implement Cells 108
Cellular Manufacturing Implementation Concerns-
How to Overcome Them 116
Costing and Justification of Cells 129
Chapter Six: Creative Rethinking for Cellular Manufacturing 133
Challenge Conventional Choices 134
Use Technology That Enables a Smaller-Scale Process
Implementation 137
Change the Sequence of Operations 140
Ask, Will the Operation Still Be Required? 142
Use Time-Slicing at the Shared Resource 142
Implement Time-Sliced Virtual Cells 144
Make the Resource Facility Behave Like a Subcontractor 148
Split into Two Cells 149
Chapter Seven: Capacity and Lot-Sizing Decisions 153
Do You Have Good Intuition About Manufacturing
System Behavior? 154
Factors Influencing Lead Time 156
A Basic Formula for Lead Time for the Single Work Center 159
Effect of Utilization on Lead Time for the Work Center 162
Impact of Lot Sizes 165
Contents ix
Impact of Setup Reduction on Lead Time 171
Lot Sizing with Multiple Products 173
The Hidden Errors in EOQ 176
Products Requiring Multiple Operations 177
Using Little s Law 183
Additional Strategies Based on System Dynamics 186
Chapter Eight: Material and Production Planning in the
QRM Enterprise 189
Rethinking Efficiency 190
Pitfalls of On-Time Delivery Measures 197
MRP: A Collection of Worst-Case Scenarios 201
Align MRP Structure with QRM Strategy 210
Using Lead Time Reduction to Continuously Improve
Your Processes 220
Chapter Nine: POLCA-The New Material Control and
Replenishment System for QRM 223
Review of Push and Pull Systems 223
Key Concepts of JIT (Lean Manufacturing) Compared with QRM 227
Misconceptions Regarding the Pull System 233
Expanding Beyond JIT Strategies-A Tale of Three Companies 234
Summary of Disadvantages of Pull or Flow Methods for QRM 239
Material Control-Don t Push or Pull, POLCA 243
Three Ds for Success of POLCA: Design, Discipline, and
Decentralization 263
Chapter Ten: Customer and Supplier Relations 267
Supplier Relations-Another Response Time Spiral at Work 268
The QRM Approach to Supplier Relations 272
Customer Relations-Another Response Time Spiral at Work 285
Your QRM Program Can Support Your Marketing Efforts 287
Apply QRM Strategies to the Entire Supply Chain 291
x Contents Part Three: Rethinking Office Operations 301
Chapter Eleven: Principles of Quick Response for
Office Operations 303
Office Operations: A Neglected Opportunity 304
The Response Time Spiral for Office Operations 309
Organizational Principles Required in the Office 314
Chapter Twelve: Tools to Support Q-ROC Implementation 335
Information Handling Principles 335
Tools to Assist in Q-ROC Implementation 338
Concerns with Implementing Office Cells 349
Chapter Thirteen: System Dynamics Principles for Quick Response 363
Strategically Plan for Idle Capacity 364
Replace Traditional Efficiency Measures 366
Eliminate Variability 367
Use Resource Pooling 369
Convert Tasks from Sequential to Parallel 371
Reduce Task Setup Times and Minimize Batching 372
Use Capacity Management and Input Control 373
Create a Flexible Organization 374
Part Four: QRM for Rapid New Product Introduction 383
Chapter Fourteen: Extending Quick Response to New
Product Introduction 385
Benefits of Rapid NPI 387
Review of NPI Methodologies 388
Concurrent Engineering for NPI 392
Management Principles for Accelerating NPI 397
Design and Manufacturing Principles 402
Organizational and System Dynamics Principles Applied to NPI 419
Rapid NPI and Your Company s Future 422
Contents xi
Part Five: Creating the QRM Enterprise 425
Chapter Fifteen: Management Mind-Set to Support QRM 427
Capacity and Facilities Decisions 428
Quality Strategies 433
Organizational Structure and Personnel Decisions 435
Production Planning and Scheduling Decisions 436
Supplier and Customer Decisions 439
Creating the QRM Mind-Set 442
Chapter Sixteen: Organizational Structure, Performance Measurement,
and Cost Systems 445
Drawbacks of Traditional Measures 446
New Measure of Performance-Introducing the QRM Number 450
Key Issues in Measuring Lead Time 458
The Team-Based Organization 469
Guidelines for Successful QRM Teams 472
Adjusting the Accounting System for QRM 487
Epilogue: Democracy in America (Revisited) 493
Chapter Seventeen: Steps to Successful Implementation of a
QRM Program 497
Fifteen Specific Steps to Implementing QRM 498
QRM: Management Headache or Opportunity? 507
Appendix 510
Endnotes 512
About the Author 534
Index 536
|
| adam_txt |
Contents
Publisher's Message xiii
Foreword xvii
Preface xxi
Acknowledgments xxv
Part One: A New Way of Thinking Stems from One Principle 1
Chapter One: QRM: Not Just Another Buzzword 3
How QRM Differs from Other Continuous Improvement
and Quality Programs 6
Implementing QRM: What Managers Believe 8
Perceptions of Implementing QRM in North American Companies 11
QRM Principles 17
Implementing QRM-The Prerequisites for Success 22
Improvement for the Entire Organization Comes from a
Single Theme 24
Chapter Two: Benefits of QRM 27
Benefits of Quick Response in Product Introduction 29
Benefits of Quick Response in Existing Production 30
Waste Due to Long Lead Times and Late Deliveries 34
Results of Quick Response Strategies 38
Benefits of Quick Response in Securing Orders 41
Benefits of QRM: Forewarned Is Forearmed 44
Chapter Three: The Response Time Spiral—Legacy of the
Scale and Cost Management Strategies 53
The Eras of Scale and Cost Strategies 54
The Response Time Spiral for Three Different Manufacturing
Environments 57
Other Policies That Promote the Response Time Spiral 67
Roots of the Response Time Spiral 69
Eliminating the Response Time Spiral 78
vii
viii Contents
Part Two: Rethinking Production and Materials Management 85
Chapter Four: Reorganizing Production 87
Seven Key Principles for Restructuring Your Company 88
The Manufacturing Cell-Creating the Product-Focused
Organization 89
Staffing and Training Cell Workers 96
Planning, Scheduling, and Control with Cells 100
Cells Foster Continuous Improvement 102
Chapter Five: Structured Methodology for Implementing Cellular
Manufacturing 107
Seven Steps to Successfully Implement Cells 108
Cellular Manufacturing Implementation Concerns-
How to Overcome Them 116
Costing and Justification of Cells 129
Chapter Six: Creative Rethinking for Cellular Manufacturing 133
Challenge Conventional Choices 134
Use Technology That Enables a Smaller-Scale Process
Implementation 137
Change the Sequence of Operations 140
Ask, Will the Operation Still Be Required? 142
Use Time-Slicing at the Shared Resource 142
Implement Time-Sliced Virtual Cells 144
Make the Resource Facility Behave Like a Subcontractor 148
Split into Two Cells 149
Chapter Seven: Capacity and Lot-Sizing Decisions 153
Do You Have Good Intuition About Manufacturing
System Behavior? 154
Factors Influencing Lead Time 156
A Basic Formula for Lead Time for the Single Work Center 159
Effect of Utilization on Lead Time for the Work Center 162
Impact of Lot Sizes 165
Contents ix
Impact of Setup Reduction on Lead Time 171
Lot Sizing with Multiple Products 173
The Hidden Errors in EOQ 176
Products Requiring Multiple Operations 177
Using Little's Law 183
Additional Strategies Based on System Dynamics 186
Chapter Eight: Material and Production Planning in the
QRM Enterprise 189
Rethinking Efficiency 190
Pitfalls of On-Time Delivery Measures 197
MRP: A Collection of Worst-Case Scenarios 201
Align MRP Structure with QRM Strategy 210
Using Lead Time Reduction to Continuously Improve
Your Processes 220
Chapter Nine: POLCA-The New Material Control and
Replenishment System for QRM 223
Review of Push and Pull Systems 223
Key Concepts of JIT (Lean Manufacturing) Compared with QRM 227
Misconceptions Regarding the Pull System 233
Expanding Beyond JIT Strategies-A Tale of Three Companies 234
Summary of Disadvantages of Pull or Flow Methods for QRM 239
Material Control-Don't Push or Pull, POLCA 243
Three Ds for Success of POLCA: Design, Discipline, and
Decentralization 263
Chapter Ten: Customer and Supplier Relations 267
Supplier Relations-Another Response Time Spiral at Work 268
The QRM Approach to Supplier Relations 272
Customer Relations-Another Response Time Spiral at Work 285
Your QRM Program Can Support Your Marketing Efforts 287
Apply QRM Strategies to the Entire Supply Chain 291
x Contents Part Three: Rethinking Office Operations 301
Chapter Eleven: Principles of Quick Response for
Office Operations 303
Office Operations: A Neglected Opportunity 304
The Response Time Spiral for Office Operations 309
Organizational Principles Required in the Office 314
Chapter Twelve: Tools to Support Q-ROC Implementation 335
Information Handling Principles 335
Tools to Assist in Q-ROC Implementation 338
Concerns with Implementing Office Cells 349
Chapter Thirteen: System Dynamics Principles for Quick Response 363
Strategically Plan for Idle Capacity 364
Replace Traditional Efficiency Measures 366
Eliminate Variability 367
Use Resource Pooling 369
Convert Tasks from Sequential to Parallel 371
Reduce Task Setup Times and Minimize Batching 372
Use Capacity Management and Input Control 373
Create a Flexible Organization 374
Part Four: QRM for Rapid New Product Introduction 383
Chapter Fourteen: Extending Quick Response to New
Product Introduction 385
Benefits of Rapid NPI 387
Review of NPI Methodologies 388
Concurrent Engineering for NPI 392
Management Principles for Accelerating NPI 397
Design and Manufacturing Principles 402
Organizational and System Dynamics Principles Applied to NPI 419
Rapid NPI and Your Company's Future 422
Contents xi
Part Five: Creating the QRM Enterprise 425
Chapter Fifteen: Management Mind-Set to Support QRM 427
Capacity and Facilities Decisions 428
Quality Strategies 433
Organizational Structure and Personnel Decisions 435
Production Planning and Scheduling Decisions 436
Supplier and Customer Decisions 439
Creating the QRM Mind-Set 442
Chapter Sixteen: Organizational Structure, Performance Measurement,
and Cost Systems 445
Drawbacks of Traditional Measures 446
New Measure of Performance-Introducing the QRM Number 450
Key Issues in Measuring Lead Time 458
The Team-Based Organization 469
Guidelines for Successful QRM Teams 472
Adjusting the Accounting System for QRM 487
Epilogue: Democracy in America (Revisited) 493
Chapter Seventeen: Steps to Successful Implementation of a
QRM Program 497
Fifteen Specific Steps to Implementing QRM 498
QRM: Management Headache or Opportunity? 507
Appendix 510
Endnotes 512
About the Author 534
Index 536 |
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| illustrated | Illustrated |
| index_date | 2024-07-02T21:24:07Z |
| indexdate | 2024-07-09T21:17:49Z |
| institution | BVB |
| isbn | 1563272016 |
| language | English |
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| publisher | Productivity Press |
| record_format | marc |
| spelling | Suri, Rajan 1952- Verfasser (DE-588)17018790X aut Quick response manufacturing a companywide approach to reducing lead times Rajan Suri New York, NY Productivity Press 1998 XXX, 544 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Manufacturing cells New products Production management Production scheduling Durchlaufzeit (DE-588)4131022-6 gnd rswk-swf Ablauforganisation (DE-588)4112443-1 gnd rswk-swf Prozessoptimierung (DE-588)4176074-8 gnd rswk-swf Kaizen (DE-588)4429179-6 gnd rswk-swf Verkürzung (DE-588)4205832-6 gnd rswk-swf Industriebetrieb (DE-588)4026813-5 gnd rswk-swf Ablaufplanung (DE-588)4122751-7 gnd rswk-swf Qualitätsmanagement (DE-588)4219057-5 gnd rswk-swf Fertigungszeit (DE-588)4154155-8 gnd rswk-swf Ablauforganisation (DE-588)4112443-1 s Durchlaufzeit (DE-588)4131022-6 s Prozessoptimierung (DE-588)4176074-8 s Kaizen (DE-588)4429179-6 s Qualitätsmanagement (DE-588)4219057-5 s DE-604 Industriebetrieb (DE-588)4026813-5 s Ablaufplanung (DE-588)4122751-7 s Fertigungszeit (DE-588)4154155-8 s Verkürzung (DE-588)4205832-6 s DE-188 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016584840&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Suri, Rajan 1952- Quick response manufacturing a companywide approach to reducing lead times Manufacturing cells New products Production management Production scheduling Durchlaufzeit (DE-588)4131022-6 gnd Ablauforganisation (DE-588)4112443-1 gnd Prozessoptimierung (DE-588)4176074-8 gnd Kaizen (DE-588)4429179-6 gnd Verkürzung (DE-588)4205832-6 gnd Industriebetrieb (DE-588)4026813-5 gnd Ablaufplanung (DE-588)4122751-7 gnd Qualitätsmanagement (DE-588)4219057-5 gnd Fertigungszeit (DE-588)4154155-8 gnd |
| subject_GND | (DE-588)4131022-6 (DE-588)4112443-1 (DE-588)4176074-8 (DE-588)4429179-6 (DE-588)4205832-6 (DE-588)4026813-5 (DE-588)4122751-7 (DE-588)4219057-5 (DE-588)4154155-8 |
| title | Quick response manufacturing a companywide approach to reducing lead times |
| title_auth | Quick response manufacturing a companywide approach to reducing lead times |
| title_exact_search | Quick response manufacturing a companywide approach to reducing lead times |
| title_exact_search_txtP | Quick response manufacturing a companywide approach to reducing lead times |
| title_full | Quick response manufacturing a companywide approach to reducing lead times Rajan Suri |
| title_fullStr | Quick response manufacturing a companywide approach to reducing lead times Rajan Suri |
| title_full_unstemmed | Quick response manufacturing a companywide approach to reducing lead times Rajan Suri |
| title_short | Quick response manufacturing |
| title_sort | quick response manufacturing a companywide approach to reducing lead times |
| title_sub | a companywide approach to reducing lead times |
| topic | Manufacturing cells New products Production management Production scheduling Durchlaufzeit (DE-588)4131022-6 gnd Ablauforganisation (DE-588)4112443-1 gnd Prozessoptimierung (DE-588)4176074-8 gnd Kaizen (DE-588)4429179-6 gnd Verkürzung (DE-588)4205832-6 gnd Industriebetrieb (DE-588)4026813-5 gnd Ablaufplanung (DE-588)4122751-7 gnd Qualitätsmanagement (DE-588)4219057-5 gnd Fertigungszeit (DE-588)4154155-8 gnd |
| topic_facet | Manufacturing cells New products Production management Production scheduling Durchlaufzeit Ablauforganisation Prozessoptimierung Kaizen Verkürzung Industriebetrieb Ablaufplanung Qualitätsmanagement Fertigungszeit |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016584840&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT surirajan quickresponsemanufacturingacompanywideapproachtoreducingleadtimes |