Verfügbarkeit: Lean production for competitive advantage

Lean production for competitive advantage: a comprehensive guide to lean methodologies and management practices

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Bibliographische Detailangaben
1. Verfasser:	Nicholas, John M. 1945- (VerfasserIn)
Format:	Buch
Sprache:	English
Veröffentlicht:	Boca Raton, Fla. [u.a.] CRC Press 2011
Ausgabe:	Rev. ed.
Schriftenreihe:	A productivity press book
Schlagworte:	Production management Lean manufacturing Costs, Industrial Quality control Lean Production Fertigungsorganisation Just-in-time-Produktion Qualitätssteigerung
Online-Zugang:	Autorenbiografie Inhaltsverzeichnis
Beschreibung:	Rev. ed. of: Competitive manufacturing management, 1998 Contents: Race without a finish line -- Fundamentals of continuous improvement -- Value added and waste elimination -- Customer-focused quality -- Small lot production -- Set-up time reduction -- Maintaining and improving equipment -- Pull production systems -- Focused factories and group technology -- Workcells and cellular manufacturing -- Standard operations -- Quality at the source and mistake-proofing -- Uniform flow and mixed-model scheduling -- Synchronizing and balancing the process -- Planning and control in pull production -- Lean production in the supply chain.
Beschreibung:	XXV, 497 S. Ill., graph. Darst.
ISBN:	9781439820964 1439820961

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adam_text	Titel: Lean production for competitive advantage Autor: Nicholas, John M. Jahr: 2011 Contents Preface................................................................................................................................xxi Acknowledgments.............................................................................................................xxv 1 Race without a Finish Line...........................................................................................1 Competitive Advantage: Better, Cheaper, Faster, More Agile.............................................2 Lean Production and Total Quality Management.............................................................3 Lean Production and the Production Pipeline...................................................................3 The Lean Difference...........................................................................................................4 Evolution of Manufacturing..............................................................................................5 The Machine That Changed the World....................................................................5 Craftsmanship Yields to Industrialization.................................................................5 Craft Production of Automobiles..............................................................................6 Ford s Mass Production System................................................................................6 Emergence of Modern Mass Production...................................................................7 Mass Production around the World..........................................................................8 Toyoda and Ohno.....................................................................................................8 Toyota Production System?Prototype for Lean Production.............................................8 Reduced Setup Times...............................................................................................9 Small Lot Production and One-Piece Flow...............................................................9 Employee Involvement and Empowerment..............................................................10 Quality at the Source...............................................................................................10 Equipment Maintenance.........................................................................................10 Pull Production.......................................................................................................11 Standard Work........................................................................................................11 Supplier Partnerships...............................................................................................11 America s Fall from Manufacturing Grace....................................................................... 12 Climbing Back.........................................................................................................13 Modern Developments............................................................................................13 The Imperative..................................................................................................................14 Organization of Book.......................................................................................................14 Notes................................................................................................................................16 Suggested Readings..........................................................................................................16 Questions..........................................................................................................................17 Research Questions...........................................................................................................17 vii SECTION I CONTINUOUS IMPROVEMENT, WASTE ELIMINATION, CUSTOMER-FOCUSED QUALITY 2 Fundamentals of Continuous Improvement...............................................................^ Continuous Improvement as Tactics and Strategy........................................................... Incremental Improvement: Kaizen.......................................................................... Innovation Improvement........................................................................................ Making the Leap.................................................................................................... Improvement as Strategy......................................................................................... Finding and Implementing Improvements....................................................................... PDCA Cycle...........................................................................................................2* Plan Step.......................................................................................................lJ Do Step.........................................................................................................29 Check Step....................................................................................................30 Act Step.........................................................................................................° Five-Why Process....................................................................................................30 Value Analysis/Value Engineering...........................................................................31 Value Analysis Procedure................................................................................31 Process Reengineering.............................................................................................33 Reengineering Fundamentals.........................................................................33 F,mployee-Driven Kaizen........................................................................................34 Kaizen Projects........................................................................................................35 Basic Problem-Solving and Improvement Tools......................................................37 Check Sheet...................................................................................................37 Histogram.....................................................................................................37 Pareto Analysis..............................................................................................38 Scatter Diagram............................................................................................40 Process Flow Chart.........................................................................................41 Cause-and-EfFect Analysis.............................................................................42 Run Diagram................................................................................................43 Value Stream Mapping...........................................................................................44 Consensus Building....................................................................................................46 Nemawashi....................................................................................... 4g A3 Report................................................................................. 4g A3 Format and Purpose.................................................................................4g A3 Process........................................................... a a Problem-Solving A3........................................................... 49 Summary................................................... ri Notes........................................... ,., Suggested Readings................................................... ? Questions.................. _,, ....................................................................................................Z 3 3 Value Added and Waste Elimination.................................................. cy Value-Added Focus..................................... ....................................,? Necessary and Unnecessary Activities................................ ........................rg Support Organization............................................ ..........................s? Employee Involvement................................... ..............................,_? Sources of Waste..............................................................................................................60 Toyota s Seven Wastes.............................................................................................60 Producing Defects.........................................................................................60 Transportation and Material Handling..........................................................61 Inventory........................................................................................................61 Overproduction.............................................................................................63 Waiting..........................................................................................................63 Processing......................................................................................................63 Motion..........................................................................................................64 Canon s Nine Wastes...............................................................................................65 Lean to Green..........................................................................................................65 Lean Principles................................................................................................................66 Simplification.........................................................................................................66 Product, Process, and Procedure Simplification.............................................66 Concurrent Engineering................................................................................69 Cleanliness and Organization.................................................................................69 Improvement Kickoff.....................................................................................69 The Five Ss.....................................................................................................71 Benefits..........................................................................................................71 Visibility.................................................................................................................73 Cycle Timing..........................................................................................................75 Agility.....................................................................................................................75 Measurement..........................................................................................................77 Grass Roots Measurement.............................................................................77 Visual Management: Information Post-Its.....................................................78 Getting to the Bottom Line...........................................................................78 Variation Reduction................................................................................................79 Lean Principles beyond Manufacturing..................................................................80 The Meaning of Lean Production.....................................................................................81 Implementation Barriers.........................................................................................82 Attitudes........................................................................................................82 Time Commitment.......................................................................................82 Quality Commitment....................................................................................83 Misunderstanding Lean Production.......................................................................83 Social Impact of Lean.............................................................................................83 First Things First....................................................................................................83 Learn as You Go.....................................................................................................84 Summary..........................................................................................................................85 Notes...............................................................................................................................86 Suggested Reading...........................................................................................................87 Questions.........................................................................................................................87 Customer-Focused Quality.........................................................................................89 Quality Defined...............................................................................................................89 Customer s Perspective............................................................................................90 Producer s Perspective.............................................................................................90 .................91 Qualityof Design............................................................................ 9] Qualityof Conformance......................................................................................... Total Quality Management.............................................................................................. TQM lntegrative Framework................................................................................. Marketing, Sales, and Finance.......................................................................J Product Design and Manufacturing Design..................................................93 Purchasing and Suppliers...............................................................................} Production Management and Frontline Workers...........................................95 95 Cuscomer Service........................................................................................... yy ... ... .......................96 Six Sigma.............................................................................................................. Statistical Interpretation.........................................................................................- DMAIC Improvement Process....-.......................................................................... 7 Belts and Certification............................................................................................98 Statistical Process Control (SPC).....................................................................................98 Control Chart.........................................................................................................99 Process Stability.................................................................................................... 100 Process Capability..................................................................................................101 Nonstatistical Process Control...............................................................................101 Empioyee Involvement and Quality Ownership.............................................................101 Frontline Worker Responsibility............................................................................101 Process Orientarion................................................................................................102 Quality Training and Education............................................................................102 lmplcmentingTQM.......................................................................................................103 Barriers to Successful TQM...................................................................................103 TQM and Lean Production............................................................................................104 Summary......................................................................................................................105 Notes..............................................................................................................................}05 Suggested Readings........................................................................................... 1Q6 Questions......................................................................... iQg SECTION II ELEMENTS OF LEAN PRODUCTION 5 Small Lot Production.........,..,......?..,.,..................... ,, Lot Size Basics............................................... ................ ]n Dollar Costs Associated with Lots................................... ...................112 Lot Sizing and Setup Reduction.......................................... ..............................n2 Kind of Lots............................................. ......................................... Lot Sizing........... ................................................. b .......................................................................... U3 ProcessandPurchaseBatch.es................................... ...............................,n Lot-for-Lot................................. ................................... Period Order Quantity............................. ^............................................ , Economic Order Quanrity...........................[ ........................................... Economic Manufacturing Quantity ...................................................nr EOQ-Based Methods: Discussion........................................................................ j!l Transfer Batches.......................... ....................................................... Lot Size Reduction... ...........................................................................118 ....................................................................................................119 Effect of Lot Size Reduction of Competitive Criteria.............................................119 Lead Time................................................................................................... 120 Carrying Cost...............................................................................................121 Setup and Handling Cost.............................................................................121 Quality........................................................................................................ 122 Flexibility.................................................................................................... 123 Case for Larger Process Batches.............................................................................125 Minimal Lot Size...................................................................................................125 Small Buffer Stock................................................................................................126 Demand Variability.....................................................................................127 Lead Time Variability.................................................................................. 127 Facilitating Small Lot Sizes............................................................................................127 Process Batches..................................................................................................... 127 Purchase Quantities.............................................................................................. 127 Transfer Batches...................................................................................................128 Delivery and Shipping Batches.............................................................................128 Continuous Improvement...............................................................................................129 Summary........................................................................................................................129 Notes.............................................................................................................................130 Questions........................................................................................................................131 6 Setup-Time Reduction..............................................................................................135 Improve Setups? Why Bother?........................................................................................135 Traditional Approaches..........................................................................................135 Find Another Way................................................................................................ 136 Benefits of Simplified Setups..................................................................................137 Setup: A Case in Neglect.......................................................................................138 Setup-Reduction Methodology.......................................................................................138 Shingo and SMED................................................................................................138 SMED Methodology for Setup Reduction............................................................139 Stage 1: Identify Internal and External Steps................................................139 Stage 2: Convert Internal Steps to External..................................................140 Stage 3: Improve All Aspects of the Setup Operation...................................141 Stage 4: Abolish Setup..................................................................................142 Techniques for Setup Reduction.....................................................................................143 Separate Internal and External Activities...............................................................143 Checklists.....................................................................................................143 Equipment Checks and Repairs....................................................................144 Setup Schedules............................................................................................144 Improve Internal Setups.........................................................................................144 Parallel Setup Tasks......................................................................................144 Attachment Devices.....................................................................................145 I Eliminate Adjustments.................................................................................147 I Improve External Setups........................................................................................149 1 Storage..........................................................................................................149 1 Setup Kits and Carts....................................................................................150 Material Handling........................................................................................150 .152 Abolish the Setup................................................................................... , _ . ................153 Setup-Reduction Projects.............................................................................. Scope of Project..................................................................................................... Setup Reduction Team.......................................................................................... Ready, Get Set, Shoot!...........................................................................................l54 Analysis of Video Recording.................................................................................. Generating and Selecting Ideas.............................................................................. 1 £ C Continuous Improvement...................................................................................... .......................157 Summary...................................................................................................... Notes....!.........................................................................................................................157 Suggested Reading..........................................................................................................15° ICO Questions........................................................................................................................ J 7 Maintaining and Improving Equipment..................................................................161 Equipment Maintenance.................................................................................................161 Breakdown Repair.................................................................................................162 Equipment Problems and Competitiveness............................................................162 Preventive Maintenance.........................................................................................163 Total Productive Maintenance...............................................................................163 Benefits of TPM...........................................................................................163 Equipment Effectiveness.................................................................................................164 Equipment Losses..................................................................................................164 Maintainability......................................................................................................165 Reliability..............................................................................................................165 Failure Pattern..............................................................................................166 Mean Time between Failure.........................................................................167 Availability............................................................................................................168 Availability and Downtime for Repair..........................................................168 Availability and All Downtime.....................................................................168 Repair Downtime Variability.......................................................................169 Efficiency.................................................................................. yjQ Rate Efficiency............................................................. yj§ Speed Efficiency............................................................. yj Quality Rate........................................................... 171 Overall Equipment Effectiveness.................................................. 172 Preventive Maintenance Program.................................... 177 Causes of Equipment Problems.............................................. 172 Maintain Normal Operating Conditions............................................. I73 Maintain Equipment Requirements................................................. I73 Keep Equipment and Facilities Clean and Organized............................ZZZZZZZZ. 174 Monitor Equipment Daily............................................ ..............,-,/ Schedule Preventive Maintenance.......................................... ..................174 Ways of Scheduling PM......................................... ...............Re- scheduled PM and Failure Pattern...................................Z.........................175 Manage Maintenance Information.......................................Z..............................179 Use Predictive Maintenance........................................... ...................................}R? Role of Opetators..... ....................................... F .............................................................................................183 Total Productive Maintenance........................................................................................184 Perform TPM Preventive Maintenance..................................................................184 Develop In-House Capability to Restore and Redesign Equipment.......................185 Eliminate Human Error in Operation and Maintenance.......................................187 Education and Training................................................................................187 Foolproofing.................................................................................................187 Improving Maintenance Procedures.............................................................189 Implementing TPM........................................................................................................191 Program Feasibility................................................................................................191 Program Objectives and Master Plan.....................................................................192 Target Areas...........................................................................................................192 Target Area Committees........................................................................................193 Plantwide Issues.....................................................................................................193 Management Support............................................................................................194 Maintenance Organization....................................................................................194 Decentralization...........................................................................................194 Central Maintenance....................................................................................195 Summary........................................................................................................................195 Notes..............................................................................................................................196 Suggested Reading..........................................................................................................197 Questions........................................................................................................................197 8 Pull Production Systems..........................................................................................201 Production Control Systems..........................................................................................202 Pull Systems and Push Systems......................................................................................202 Pull Production Process........................................................................................203 Why Pull Production Cannot Be Stockless...........................................................204 Push Production Process.......................................................................................206 Pull Production and Push Production Contrasted................................................209 Containers and Cards...........................................................................................209 Rules for Pull Production......................................................................................210 How to Achieve Pull Production....................................................................................211 Pull System as a Fixed-Quantity/Reorder-Point System.........................................212 Containers in a Buffet............................................................................................214 Container Size..............................................................................................214 Material Handling........................................................................................214 Outbound and Inbound Buffers...................................................................215 Conveyance Kanbans............................................................................................216 Production Kanbans..............................................................................................218 Safety Factor................................................................................................220 Another Single-Card System.................................................................................220 Signal Kanban.......................................................................................................221 What, More Cards?..............................................................................................225 Express Card...............................................................................................225 Temporary Card..........................................................................................226 Odd-Number Card.....................................................................................226 Other Mechanisms for Signal and Control.................................................................... Wheeled Carts...................................................................................................... ._ Kanban Squares.................................................................................................... Golf Balls.............................................................................................................. Electronic Kanban................................................................................................ Clothespin Clips................................................................................................... Milk Run..............................................................................................................j£ Kanban Sequence Board....................................................................................... 232 Process Improvement..................................................................................................... Practical Matters............................................................................................................ Necessary Conditions for Pull Production.............................................................233 Pull Production and Repetitive Production..........................................................234 When Pull Does Not Work..................................................................................234 Pull and Push Systems, Both at Once....................................................................235 Getting Started......................................................................................................235 Summary.......................................................................................................................23o Notes.............................................................................................................................237 Suggested Reading.........................................................................................................237 Questions.......................................................................................................................237 Focused Factories and Group Technology...............................................................243 Ways of Doing Work.....................................................................................................244 Variety-Efficiency Tradeoff...................................................................................245 Facilities Layout..............................................................................................................245 Fixed-Position Layout............................................................................................245 Process Layout......................................................................................................246 Product Layout......................................................................................................247 Variety-Volume Ttadeoff......................................................................................248 Group Technology..........................................................................................................249 Product Coding and Classification Schemes..........................................................249 Hierarchical (Monocode) Sttuctute..............................................................249 Chain (Polycode) Structure..........................................................................250 Hybrid Structure....................................................................... 251 Product Families and Focused Factories...............................................................251 GT and Product Design................................................... 251 To Code or Not to Code.............................................. 252 Focused Factory......................................... ,? On What to Focus............................................ 2=,2 Microdesign Issues.............................................. jr( Flexible Flow Lines............................................ 256 Flexible U-Lines and S-Lines.............................................. .................257 Working Out the Final Layout........................................ ......................257 Product-Quantity Analysis............................................. .........................................?,R Establishing Product and Machine Groups.....................ZZZZZZZZ................................259 Coding and Classification...................................... ...................................»rn Cluster Analysis............ .........................................?^? 7 ...........................................................................................260 Production Flow Analysis......................................................................................261 Binary Ordering Algorithm.........................................................................262 Dense Blocks, Then What?....................................................................................265 Advantages and Disadvantages of Focused Factories..............................................267 Summary.......................................................................................................................269 Notes..............................................................................................................................270 Suggested Reading..........................................................................................................271 Questions........................................................................................................................271 10 Workcells and Cellular Manufacturing...................................................................275 Workcell Concepts..........................................................................................................276 Workstations, Workers, and Machines...................................................................276 Workcell Output and Number of Workers............................................................276 Workcell Applications....................................................................................................277 Typical Workcell End Items..................................................................................277 Linked Workcells and Subcells.............................................................................277 Wotkcell Design............................................................................................................280 Brief Digression: Cycle Time Concept..................................................................280 Assembly Workcells...............................................................................................281 Machining Workcells............................................................................................285 Workcell Capacity................................................................................................288 Cost-Capacity Tradeoff Analysis..........................................................................289 Cells for Batch Size = 1..................................................................................................290 Sequential Changeover Tasks.................................................................................291 Productivity Improvement....................................................................................292 Quality Control.....................................................................................................293 Workcells Beyond Manufacturing.........................................................................293 Workers in Cells............................................................................................................294 Staffing a Workcell...............................................................................................294 Simultaneous Staffing of Multiple Cells................................................................295 Equipment Issues...........................................................................................................296 Machine Sharing..................................................................................................296 Machine Acquisition.............................................................................................297 Special Operations................................................................................................297 Cell Automation............................................................................................................298 Implementing Cellular Manufacturing..........................................................................299 Planning and Control...........................................................................................299 Organizational Issues............................................................................................300 Roles and Responsibilities............................................................................300 Incentive Plans.............................................................................................301 Time and Rate Standards.............................................................................301 Team Education and Training.....................................................................303 Attitudinal Issues..................................................................................................304 Shop-Floor Workers.....................................................................................304 Supervisors..................................................................................................304 Management................................................................................................304 .....................................305 Getting Started......................................................................... ^rj;, Summary.............................................................................................. ^q^ Notes....................................................................................................... QQ7 Suggested Readings....................................................................................................... Questions...................................................................................................... .......311 11 Standard Operations..................................................................................... Standard Operations....................................................................................................... Shop-Floor Relevancy............................................................................................31 Shop-Floor Involvement........................................................................................¦* Benefits.................................................................................................................. T UT. ..............................313 lakt 1 lme........................................................................................................ Completion Time Per Unit.............................................................................................313 Time to Complete a Task of an Operation............................................................313 Completion Time per Unit....................................................................................315 Production Capacity..............................................................................................316 Standard Operations Routine.........................................................................................316 Kinds of SORs.......................................................................................................316 SOR Sheet.............................................................................................................317 Operations Routine and Process Routing Sequence..............................................320 Idle Time...............................................................................................................321 Standard Quantity of WIP.............................................................................................321 Standard Operations Sheet............................................................................................322 Improvement Tool................................................................................................323 Conditions for Successful Standard Operations.............................................................326 Standard Operations in the Service Sector......................................................................327 Summary.......................................................................................................................328 Notes.............................................................................................................................328 Suggested Reading..........................................................................................................329 Questions......................................................................................................................329 12 Quality at the Source and Mistake-Proofing...........................................................331 SPG Limitations............................................................... aaj 100% Inspection (Screening)........................................ 332 Self-Checks and Successive Checks............................................................332 Self-Checks.............................................. -i-xry Successive Checks........................................... ^32 Requirements for Self-Checks and Successive Checks............................................333 Check Targets..................................... -,.,;, Feedback and Action.... 222 ? .. ................................................................................ODD Consideration and Support for Workers.................................... 334 Automation.................................... .................. - Gycle Time.............................................................. Pursuit of Perfection: Limits of Inspection ........................................,« Jidoka............ ...........................................................i5b ............?.......................................................... x xC Autonomation.............. Andons............... ...........................................................................................336 ................................................................................................336 K^ Source Inspection and Pokayoke.....................................................................................337 Source Inspection..................................................................................................338 Pokayoke Functions..............................................................................................340 Regulatory Pokayokes..................................................................................340 Setting Pokayokes........................................................................................340 Pokayoke Ideas.....................................................................................................342 Continuous Improvement.....................................................................................344 Summary.......................................................................................................................344 Notes..............................................................................................................................345 Suggested Reading.........................................................................................................346 Questions.......................................................................................................................346 SECTION III LEAN PRODUCTION PLANNING, CONTROL, AND SUPPLY CHAINS 13 Uniform Flow and Mixed-Model Scheduling...........................................................351 Production Leveling........................................................................................................351 Leveling Production with Buffer Stocks.................................................................353 Leveling Production with Uniform Schedules.......................................................353 Requirements for Leveling Production Schedules..................................................355 Continuous, Stable Demand........................................................................355 Short Setup Times........................................................................................356 Production = Demand..................................................................................356 Leveling Focus.......................................................................................................356 Leveling the Master Schedule................................................................................357 Leveling One Product Group.......................................................................357 Leveling Multiple Products...........................................................................358 Leveled Schedules: A Cooperative Effort...............................................................361 Level Scheduling in Pull Production..............................................................................362 Mixed-Model Production.....................................................................................362 Final Assembly Schedule.............................................................................362 Heijunka: Mixed-Model Production...........................................................363 Batch Size....................................................................................................363 MMP and Production Smoothing...............................................................363 The MMP Schedule..............................................................................................364 Requirements for MMP.........................................................................................365 Flexible Workers..........................................................................................366 Effective Quality Assurance.........................................................................366 Small-Lot Material Supply...........................................................................366 Advantages of MMP.............................................................................................366 Elimination of Losses Due to Line Changeover...........................................366 Process Improvement....................................................................................367 Balanced Work Loads...................................................................................367 Fewer Losses from Material Shortages..........................................................367 Production Planning and Scheduling in Different Circumstances..................................367 Production Philosophy...........................................................................................367 Make to Stock..............................................................................................367 xviii ¦ Contents ,, ? , .........................368 Assemble to Order........................................................... Make to Order............................................................................................. Final Assembly Scheduling versus Master Production Scheduling.................................W MTS: Uniform Load Production Schedule............................................................_ Assemble to Order................................................................................................. Modular Bills............................................................................................... Modularization Procedure............................................................................i/- Planning Bills...............................................................................................3?l Alternative to Planning Bills.........................................................................¦ ,° Role of Concurrent Engineering...................................................................376 Make to Order......................................................................................................377 Scheduling with Backlogs............................................................................377 Minimizing Scheduling Problems................................................................378 Hybrid Systems.....................................................................................................380 Summary........................................................................................................................DO Notes.............................................................................................................................382 Suggested Reading.........................................................................................................383 Questions.......................................................................................................................383 14 Synchronizing and Balancing the Process................................................................389 Synchronization.............................................................................................................389 Synchronized Cycle Times....................................................................................390 The Essence of Cycle Time....................................................................................392 Bottleneck Scheduling....................................................................................................393 Principles...............................................................................................................393 Throughput Pace..........................................................................................393 Buffer Stock..................................................................................................393 Process Scheduling.....................................................................................393 Drum-Buffer-Rope.................................................................. 393 Pull from Bottleneck......................................................... 394 Balancing................................................................................................................ 394 Line Balancing........................................................ ^qc Balancing for MMP................................................. 207 Other Ways to Achieve Balance.................................................... 400 Dynamic Balance.............................................. 400 Parallel Line............................................ /«n Balancing for Synchronous Flow........................................ ...................401 Balancing through Worker Reassignment................................... ......................402 Maintaining Synchronization.................................... ..............................4fH Adapting to Schedule Changes................................. ^............................................4?4 Alter the Production Workday............................. ..............................................,?, Alter the Production Rate (Adjust Cycle Time) .... . 405 In Practice: Adjusting to Schedule Ghan^ .............................. Summary. In Practice: Adjusting to Schedule Changes.... ...... ZZZZZZZZZZZZZZZZ...........405 Notes.... ..... ..............................................................................................................406 Suggested Readings............................ ..................................................................407 Questions......... ...............................................................407 ..........................................................................................................407 M Contents ¦ xix 15 Planning and Control in Pull Production................................................................411 The Whole Enchilada.....................................................................................................412 Centralized System................................................................................................412 Decentralized System.............................................................................................413 Centralized Planning and Control System......................................................................414 Monthly Planning.................................................................................................414 Planning MPSs for Future Periods................................................................414 MPSs for Shop Floor Planning.....................................................................415 Daily Scheduling...................................................................................................415 Integrating Recent Demand Information.....................................................415 Daily Order Alterations................................................................................416 Material Procurement Forecast.....................................................................417 Kanban Supplier Link..................................................................................417 MRP Supplier Link......................................................................................418 Decentralized Planning and Control System..................................................................418 Detailed Capacity Planning...................................................................................418 Initial Capacity Planning..............................................................................418 Capacity Fine-Tuning...................................................................................419 Shop-Floor Control.........................................................................................................419 Visual Management, Again...................................................................................419 Role of Worker Teams..................................................................................419 Adapting MRP-Based PPC Systems to Pull Production.................................................420 Simplified Bills of Materials..................................................................................420 FlatBOMs....................................................................................................421 Phantom Records........................................................................................423 Stock Areas and Point of Use................................................................................424 Postdeduct and Deduct Lists................................................................................426 Rate-Based Master Schedules................................................................................427 Implementing Pull Production with MRP PPC...................................................428 Step 1: Create a Logical Flow; Improve Material Handling.........................429 Step 2: Introduce the Pull System................................................................429 Step 3: Create a New Layout; Reduce Reliance on MRP.............................430 Step 4: Continuously Improve Processes......................................................430 Summary.......................................................................................................................430 Notes..............................................................................................................................431 Suggested Readings.......................................................................................................432 Questions.......................................................................................................................432 16 Lean Production in the Supply Chain......................................................................437 Produce versus Buy........................................................................................................438 Relying on Suppliers......................................................................................................438 Core Competency.................................................................................................438 Supply Chain Management...........................................................................................439 Process and Customer Focus.................................................................................440 Customer-Supplier Relationships..................................................................................440 Joint Problem Solving...........................................................................................441 xx ¦ Contents 441 Quality at the Source........................................................................................ Information Sharing............................................................................................. Partnership Relationships..................................................................................... Purchase Criteria......................................................................................... 443 Design Source............................................................................................. Number of Suppliers.................................................................................... Type of Agreement......................................................................................4 Terms of Agreement....................................................................................444 Customer-Supplier Interaction...................................................................445 It Doesn t Come Easy..................................................................................447 Small-Customer, Big-Suppliet Partnership..................................................448 Supplier Selection..........................................................................................................44o Certification.........................................................................................................448 Certification by Customer...........................................................................449 Certification by Industry Standard or Award................................................450 Evaluation..............................................................................................................450 Purchasing......................................................................................................................451 Evolution of Purchasing.........................................................................................451 Role of Purchasing in Lean Production.................................................................451 Lean in the Supply Chain...............................................................................................453 Facilities Layout.....................................................................................................453 Teamwork..............................................................................................................455 Setup Reduction and Small-Batch Shipping..........................................................455 Preventive Maintenance.........................................................................................458 Kanban..................................................................................................................458 Communication and Scheduling..........................................................................460 Share Plans, Maintain Uniform Schedules..................................................460 Point-to-Point Communication...................................................... 461 Getting Started: Begin at Home.............................................................. 463 Summary.......................................................................................................... 4^ Appendix: Supplier Kanban.............................................. as a Notes........................................................................................ZZZZZZZZZZZZZZZZZZ. 466 Suggested Readings............................................ 4( 7 Questions........................................................ -,_ IndeX.................................................................................................................................471 About the Author................... ...........................................................................................499
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callnumber-label	TS155
callnumber-raw	TS155 TS155 .N43 2011
callnumber-search	TS155 TS155 .N43 2011
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callnumber-subject	TS - Manufactures
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ctrlnum	(OCoLC)705816521 (DE-599)BVBBV036671483
dewey-full	658.5
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dewey-search	658.5
dewey-sort	3658.5
dewey-tens	650 - Management and auxiliary services
discipline	Wirtschaftswissenschaften
edition	Rev. ed.
format	Book
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id	DE-604.BV036671483
illustrated	Illustrated
indexdate	2024-08-01T11:16:30Z
institution	BVB
isbn	9781439820964 1439820961
language	English
lccn	2010001495
oai_aleph_id	oai:aleph.bib-bvb.de:BVB01-020590572
oclc_num	705816521
open_access_boolean
owner	DE-703 DE-M347 DE-862 DE-BY-FWS DE-863 DE-BY-FWS DE-Aug4 DE-860
owner_facet	DE-703 DE-M347 DE-862 DE-BY-FWS DE-863 DE-BY-FWS DE-Aug4 DE-860
physical	XXV, 497 S. Ill., graph. Darst.
publishDate	2011
publishDateSearch	2011
publishDateSort	2011
publisher	CRC Press
record_format	marc
series2	A productivity press book
spellingShingle	Nicholas, John M. 1945- Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices Production management Lean manufacturing Costs, Industrial Quality control Lean Production (DE-588)4287302-2 gnd Fertigungsorganisation (DE-588)4140651-5 gnd Just-in-time-Produktion (DE-588)4140040-9 gnd Qualitätssteigerung (DE-588)4176587-4 gnd
subject_GND	(DE-588)4287302-2 (DE-588)4140651-5 (DE-588)4140040-9 (DE-588)4176587-4
title	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices
title_alt	Competitive manufacturing management
title_auth	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices
title_exact_search	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices
title_full	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices John Nicholas
title_fullStr	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices John Nicholas
title_full_unstemmed	Lean production for competitive advantage a comprehensive guide to lean methodologies and management practices John Nicholas
title_short	Lean production for competitive advantage
title_sort	lean production for competitive advantage a comprehensive guide to lean methodologies and management practices
title_sub	a comprehensive guide to lean methodologies and management practices
topic	Production management Lean manufacturing Costs, Industrial Quality control Lean Production (DE-588)4287302-2 gnd Fertigungsorganisation (DE-588)4140651-5 gnd Just-in-time-Produktion (DE-588)4140040-9 gnd Qualitätssteigerung (DE-588)4176587-4 gnd
topic_facet	Production management Lean manufacturing Costs, Industrial Quality control Lean Production Fertigungsorganisation Just-in-time-Produktion Qualitätssteigerung
url	http://www.loc.gov/catdir/enhancements/fy1112/2010001495-b.html http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=020590572&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
work_keys_str_mv	AT nicholasjohnm leanproductionforcompetitiveadvantageacomprehensiveguidetoleanmethodologiesandmanagementpractices AT nicholasjohnm competitivemanufacturingmanagement

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