Manufacturing at warp speed: optimizing supply chain financial performance ; includes simplified drum-buffer-rope
Gespeichert in:
| Hauptverfasser: | , |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
Boca Raton, Fla. [u.a.]
St. Lucie Press [u.a.]
2001
|
| Schriftenreihe: | TheCRC press series on constraints management
|
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XXVIII, 342 S. Ill., graph. Darst. |
| ISBN: | 1574442937 9781574442939 |
Internformat
MARC
| LEADER | 00000nam a2200000 c 4500 | ||
|---|---|---|---|
| 001 | BV042170355 | ||
| 003 | DE-604 | ||
| 005 | 20141211 | ||
| 007 | t | ||
| 008 | 141106s2001 ad|| |||| 00||| eng d | ||
| 020 | |a 1574442937 |9 1-57444-293-7 | ||
| 020 | |a 9781574442939 |9 9781574442939 | ||
| 035 | |a (OCoLC)898203829 | ||
| 035 | |a (DE-599)BVBBV042170355 | ||
| 040 | |a DE-604 |b ger |e rakwb | ||
| 041 | 0 | |a eng | |
| 049 | |a DE-862 | ||
| 084 | |a QP 500 |0 (DE-625)141894: |2 rvk | ||
| 100 | 1 | |a Schragenheim, Eli |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Manufacturing at warp speed |b optimizing supply chain financial performance ; includes simplified drum-buffer-rope |c Eli Schragenheim ; H. William Dettmer |
| 264 | 1 | |a Boca Raton, Fla. [u.a.] |b St. Lucie Press [u.a.] |c 2001 | |
| 300 | |a XXVIII, 342 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 490 | 0 | |a TheCRC press series on constraints management | |
| 700 | 1 | |a Dettmer, H. William |e Verfasser |4 aut | |
| 856 | 4 | 2 | |m HBZ Datenaustausch |q application/pdf |u http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=027609793&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |3 Inhaltsverzeichnis |
| 999 | |a oai:aleph.bib-bvb.de:BVB01-027609793 | ||
Datensatz im Suchindex
| DE-BY-862_location | 2000 |
|---|---|
| DE-BY-FWS_call_number | 2000/QP 500 S377 |
| DE-BY-FWS_katkey | 530886 |
| DE-BY-FWS_media_number | 083000511779 083000511780 |
| _version_ | 1806176889567444992 |
| adam_text | Contents
Preface
Introduction 1
Case Study: Reliable Manufacturing, Inc.
What Are Our Requirements for a Solution?
Four Parts
Learning Outcomes
PART I Managing System Constraints
1 Systems Thinking: The Foundation 13
System vs. Process
Work Flow vs. the Organization Chart
Suboptimization
Local vs. System Optima
Systems as Chains
The Manufacturing Chain
The Expanded Manufacturing Chain
The Eternal Constraint
The Importance of Knowing What the System Constraint Is
2 Principles and Tools of the Theory of Constraints 23
Constraint Management Assumption #1
Constraint Management Assumption #2
Constraint Management Assumption #3
The Airplane Analogy
The Nero Effect
vii
viii
Implications of Assumption #3
The Theory of Constraints Approach to System Management
The Five Focusing Steps
The TOC Perspective: A Summary
Ramifications of the Five Focusing Steps
3 Assessing System Success 39
Evaluating Operating Decisions: The Traditional Approach
Evaluating Operating Decisions: The TOC Approach
Relation of T, I, and OE to Traditional Business Measures of Merit
What Should Our Priorities Be?
T, I, and OE: An Example
Throughput (Constraint) Accounting
4 Constraint Management Tools 49
Types of Constraints
Constraint Types: Examples
The Logical Thinking Process
Critical Chain
Drum-Buffer-Rope Production Scheduling
The Five Focusing Steps Revisited
5 How Work Flows through a Manufacturing Process 59
The A Flow
The V Flow
The I Flow
The T Flow
Various Manufacturing Environments and Their Specific Problems
PART II Traditional Drum-Buffer-Rope
6 Applying Constraints Theory to
Manufacturing Operations 73
The Simple Production Organization
Injections: Breaking Conflict #1
Transfer Batches
Injections: Breaking Conflict #2
Injections: Breaking Conflict #3
ix
Future Reality Tree: Plant 120
Generic Manufacturing Conflict
7 Traditional Drum-Buffer-Rope 99
What DBR Does
What DBR Does Not Do
Some Basic DBR Principles
Guidelines for DBR Shop Floor Planning
DBR Basic Concepts
The Control Conflict: Detail or No Detail?
Buffers: Traditional DBR
Preliminary Actions
The Control Conflict Revisited
Managing Non-Constraints in a DBR Environment
8 Traditional Buffer Management: The DBR
Control Mechanism 123
The Buffer Concept
Buffer Management
DBR Buffers: Three Zones
Holes in a Buffer
How a Hole in a Buffer Appears in the Master Production Schedule
DBR Buffer Zones: A CCR Example
Three Benefits of Buffer Management
How to Realize the Benefits of Buffer Management
Identifying an Emerging Constraint: An Example
9 Drum-Buffer-Rope (DBR) and Manufacturing
Resource Planning (MRP) 137
MRP Advantages
MRP Disadvantages
MRP Policies That Can Create Problems
Overcoming MRP s Disadvantages
MRP Lead Times and Queues
Establishing the Rope
Problems in DBR Implementation within MRP Systems
DBR-Specific Software and Dynamic Buffers
Summary
X
PART III Simplified Drum-Buffer-Rope
10 Simplified Drum-Buffer Rope (S-DBR) 149
Difficulties in Applying Traditional DBR
S-DBR: Simplified, Effective
S-DBR: Basic Assumptions
S-DBR: Operating Principles
S-DBR: A Graphic Depiction
Implementing Simplified DBR
S-DBR Control
S-DBR Problem Situations
Traditional DBR and S-DBR: Which to Use When?
11 Controlling Uncertainty and Variation:
The S-DBR Approach 175
Buffers: A Quick Review
Definition of Control
Objectives of Red-Line Control (Buffer Management)
How Red-Line Control Works
Red-Line Control for Raw Materials
Red-Line Control: Limitations
Planned Load: An Important Control Information Source
Rough-Cut Capacity as a Control Mechanism
Control in S-DBR: A Summary
Plant ADV200: An S-DBR Simulation
12 Managing Excess Capacity 209
Excess Capacity: What Can We Do with It?
Excess Capacity: Protection from What?
The Dilemma of Maintaining Excess Capacity
The Excess Capacity Conflict
Effects of Various Policies on Actual Production Lead Time
Excess Capacity: A New Way to Think about It
Common Reasons Why Excess Capacity Remains Hidden
The Cost Mentality and Excess Capacity
When is Excess Too Much?
How to Prepare for Excess Capacity
How to Expose Excess Capacity
Summary
xi
( PART IV Optimizing Decisions
13 Throughput-Based Decision Support 225
Management s Problem
Management s Challenge
Traditional Global Measurements
TOC Global Measurements
Link between TOC and Traditional Global Financial Measurements
How T, I, and OE Support Daily Decisions
Calculating the Financial Impact
The Logic of Measurements
How T, I, and OE Support Daily Decisions: Another Example
Using T, I, and OE in Making Daily Decisions
How to Load the CCR and Maximize T without Increasing OE and I
Throughput-per-Constraint-Unit Rule: An Example
When No CCR Exists: Decision Rules
How Do Big Decisions Differ from Small Ones?
How to Determine AT
How to Determine AOE and AI
The TOC Decision Rule
14 Drum-Buffer-Rope (DBR) and Enterprise Resource
Planning (ERP) 245
Think E, Manage E : Management in the ERP Era
Case Study: SMPRO, Inc.
Problems Related to Information at SMPRO
ERP Implementation: Basic Assumptions
The Second ERP Assumption
The Third ERP Assumption
Why ERP?
TOC Support in an ERP System
Supply Chain Management
Conclusion: Lessons Learned
Appendices 263
Appendix A:The Dice Game
Appendix B: The Management Interactive Case Study Simulator (MICSS)
Appendix C:Plant 120
Appendix D:The ADV200 Company
xii
Bibliography 331
Index 333
List of Figures
Figure I.I Generic Manufacturing Current Reality Tree 5
Figure 1.1 Generic System 14
Figure 1.2 Work Flow vs. the Organization Chart 15
Figure 1.3 Deming on System Optimization 18
Figure 1.4 The Manufacturing Chain 19
Figure 1.5 The Expanded Manufacturing Chain 20
Figure 2.1 Capacity and Demand 29
Figure 2.2 Assumption #3: Current Reality Tree 30
Figure 3.1 Net Profit and Return on Investment 43
Figure 3.2 Management Priorities 43
Figure 3.3 Limits to T, I, and OE 45
Figure 3.4 Boeing Article #1 (USA Today) 47
Figure 3.5 Boeing Article #2 (Seattle Times) 48
Figure 4.1 BLM Paint Article (Peninsula Daily News) 52
Figure 4.2 Necessary Condition Relationship (Example) 55
Figure 4.3 Five Focusing Steps: Strategic as Well as Tactical 57
Figure 5.1 A Flow 60
Figure 5.2 V Flow 61
xiii
xiv
Figure 5.3 I Flow 61
Figure 5.4 T Flow 62
Figure 6.1 Generic Manufacturing Current Reality Tree 75
Figure 6.2 Plant 120 Current Reality Tree 77
Figure 6.3 Conflict #1: Local Efficiency 79
Figure 6.3(r) Conflict #1: Local Efficiency (Revised) 81
Figure 6.4 Conflict #2: Unreliable Supplier 82
Figure 6.5 Conflict #3: Information Overload 83
Figure 6.6 Injections for Plant 120 Conflict #1 85
Figure 6.7 Injections for Plant 120 Conflict #2 86
Figure 6.8 Safety Stock vs. Emergency Stock: An Example 89
Figure 6.9 Injections for Plant 120 Conflict #3 91
Figure 6.10 Plant 120 Future Reality Tree 92
Figure 6.11 Plant 120 Negative Branch #1 94
Figure 6.12 Plant 120 Negative Branch #2 95
Figure 6.13 Generic Manufacturing Conflict 96
Figure 6.14 Injections for Generic Manufacturing Conflict 97
Figure 7.1 Basic DBR Concept 103
Figure 7.2 The Control Conflict 104
Figure 7.3 A Typical Manufacturing Process 105
Figure 7.4 Shipping Buffer 107
Figure 7.5 CCR Buffer 108
Figure 7.6 Assembly Buffer 108
Figure 7.7 Material Flow Map by Product 109
Figure 7.8 Traditional DBR: The Big Picture 113
Figure 7.9 Traditional DBR Scheduling: An Example 114
Figure 7.10 The Control Conflict Revisited 120
Figure 8.1 DBR Buffers: Three Zones 125
XV
Figure 8.2 Holes in a Buffer 127
Figure 8.3 Holes in the Shipping Buffer 128
Figure 8.4 Work Order #49 130
Figure 8.5 Buffer Holes in a Master Production Schedule 131
Figure 8.6 Hole in a CCR Buffer 132
Figure 8.7 DBR Buffer (Example) 133
Figure 10.1 Stealing (An Example) 154
Figure 10.2 Operator Confusion 156
Figure 10.3 Demand and Capacity 157
Figure 10.4 A Potential CCR 159
Figure 10.5 Current Reality Tree: Protective Capacity 160
Figure 10.6 S-DBR: A Graphic Depiction 164
Figure 10.7 The S-DBR Implementation Process 168
Figure 11.1 Planned Load 180
Figure 11.2 Rough-Cut Capacity 183
Figure 11.3 ADV200 Current Reality Tree #1 185
Figure 11.4 ADV200 Conflict: Quoted Lead Time 189
Figure 11.5 ADV200 Future Reality Tree #1 192
Figure 11.6 ADV Current Reality Tree #2:
Anticipating Overload 195
Figure 11.7 ADV200 Future Reality Tree #2:
A Control System 197
Figure 11.8 ADV200 Product Prioritization 199
Figure 11.9 ADV200 Future Reality Tree #3:
Manipulating Demand 201
Figure 11.10 Future Reality Tree: Managing System
Constraint Dynamics 205
Figure 12.1 Resource Capacity Profile 210
Figure 12.2 Future Reality Tree: Excess Capacity 211
xvi
Figure 12.3 Parkinson s Law Applied to Excess Capacity 214
Figure 12.4 Excess Capacity Conflict 216
Figure 12.5 Effects of Various Policies on Actual Production
Lead Time 217
Figure 12.6 Managing By T, I, and OE 218
Figure 13.1 Price Reduction: To Give Or Not to Give? That is the
question 231 ,
Figure 13.2 Differences between Traditional Cost Accounting
and TBDS 232
Figure 13.3 The Traditional Accounting Answer 233
Figure 13.4 The TBDS Answer 234
Figure 13.5 The Logic of Measurements 235
Figure 13.6 Rules for Changes in Profit and Investment 242
Figure 13.7 The Impact of a Big Decision on the Product
Priority Scheme 243
Figure 14.1 Generic Manufacturing Current Reality Tree 246
List of Figures: Appendices
Figure A.1 Dice Game Layout 264
Figure A.2 Net Profit and ROI Formulas 265
Figure A.3 Production Worksheet 267
Figure A.4 Team Totals 269
Figure B.I Marketing View 278
Figure B.2 Marketing View | Information 281
Figure B.3 Marketing View | Information | Sales
Summary Graph 283
Figure B.4 Marketing View | Policies 284
Figure B.5 Marketing View | Policies | Product Parameters 284
Figure B.6 Help Menu 286
xvii
Figure B.7 Production View 287
Figure B.8 Production View | Information 288
Figure B.9 Production View | Information | Machines
Utilization 289
Figure B.10 Production View | Information | Work Order Status.... 290
Figure B.ll Production View | Information | Master Production
Schedule 291
Figure B.I2 Production View | Information | All Products
Routing 292
Figure B.13 Production View | Policies 292
Figure B.14 Production View | Policies | Raw Material Release |
Immediate 293
Figure B.I5 Production View | Policies | Raw Material
Release | MRP 293
Figure B.I6 Production View | Policies | Machine Policy |
Dispatch Policy 294
Figure B.I7 Production View | Policies | Machine Policy | WO
Acceptance 295
Figure B.18 Production View | Policies | Work Order Planning |
Planning Frequency (Weekly) 296
Figure B.I9 Production View | Policies | Work Order Planning |
Planning Frequency (Fixed Interval) 297
Figure B.20 Production View | View Total Load 299
Figure B.21 Purchasing View 300
Figure B.22 Purchasing View | Information 301
Figure B.23 Purchasing View | Information | Suppliers Average Lead
Time 302
Figure B.24 Purchasing View | Actions 303
Figure B.25 Purchasing View | Actions | Suppliers 303
Figure B.26 Purchasing View | Policies 304
Figure B.27 Purchasing View | Policies | Material Parameters 304
xviii
Figure B.28 Finance View 305
Figure B.29 Finance View | Information 306
Figure B.30 Finance View | Information | Product Cost
Analysis 307
Figure B.31 Finance View | Information | Product Throughput
Summary 307
Figure B.32 Session Menu 308
Figure B.33 Session | Information 309
Figure C.I Plant 120 Management Report 315
Figure C.2 Plant 120 Quick-Reference Policy Matrix 318
Figure D.I ADV200 Quick-Reference Policy Matrix 329
|
| any_adam_object | 1 |
| author | Schragenheim, Eli Dettmer, H. William |
| author_facet | Schragenheim, Eli Dettmer, H. William |
| author_role | aut aut |
| author_sort | Schragenheim, Eli |
| author_variant | e s es h w d hw hwd |
| building | Verbundindex |
| bvnumber | BV042170355 |
| classification_rvk | QP 500 |
| ctrlnum | (OCoLC)898203829 (DE-599)BVBBV042170355 |
| discipline | Wirtschaftswissenschaften |
| format | Book |
| fullrecord | <?xml version="1.0" encoding="UTF-8"?><collection xmlns="http://www.loc.gov/MARC21/slim"><record><leader>01295nam a2200313 c 4500</leader><controlfield tag="001">BV042170355</controlfield><controlfield tag="003">DE-604</controlfield><controlfield tag="005">20141211 </controlfield><controlfield tag="007">t</controlfield><controlfield tag="008">141106s2001 ad|| |||| 00||| eng d</controlfield><datafield tag="020" ind1=" " ind2=" "><subfield code="a">1574442937</subfield><subfield code="9">1-57444-293-7</subfield></datafield><datafield tag="020" ind1=" " ind2=" "><subfield code="a">9781574442939</subfield><subfield code="9">9781574442939</subfield></datafield><datafield tag="035" ind1=" " ind2=" "><subfield code="a">(OCoLC)898203829</subfield></datafield><datafield tag="035" ind1=" " ind2=" "><subfield code="a">(DE-599)BVBBV042170355</subfield></datafield><datafield tag="040" ind1=" " ind2=" "><subfield code="a">DE-604</subfield><subfield code="b">ger</subfield><subfield code="e">rakwb</subfield></datafield><datafield tag="041" ind1="0" ind2=" "><subfield code="a">eng</subfield></datafield><datafield tag="049" ind1=" " ind2=" "><subfield code="a">DE-862</subfield></datafield><datafield tag="084" ind1=" " ind2=" "><subfield code="a">QP 500</subfield><subfield code="0">(DE-625)141894:</subfield><subfield code="2">rvk</subfield></datafield><datafield tag="100" ind1="1" ind2=" "><subfield code="a">Schragenheim, Eli</subfield><subfield code="e">Verfasser</subfield><subfield code="4">aut</subfield></datafield><datafield tag="245" ind1="1" ind2="0"><subfield code="a">Manufacturing at warp speed</subfield><subfield code="b">optimizing supply chain financial performance ; includes simplified drum-buffer-rope</subfield><subfield code="c">Eli Schragenheim ; H. William Dettmer</subfield></datafield><datafield tag="264" ind1=" " ind2="1"><subfield code="a">Boca Raton, Fla. [u.a.]</subfield><subfield code="b">St. Lucie Press [u.a.]</subfield><subfield code="c">2001</subfield></datafield><datafield tag="300" ind1=" " ind2=" "><subfield code="a">XXVIII, 342 S.</subfield><subfield code="b">Ill., graph. Darst.</subfield></datafield><datafield tag="336" ind1=" " ind2=" "><subfield code="b">txt</subfield><subfield code="2">rdacontent</subfield></datafield><datafield tag="337" ind1=" " ind2=" "><subfield code="b">n</subfield><subfield code="2">rdamedia</subfield></datafield><datafield tag="338" ind1=" " ind2=" "><subfield code="b">nc</subfield><subfield code="2">rdacarrier</subfield></datafield><datafield tag="490" ind1="0" ind2=" "><subfield code="a">TheCRC press series on constraints management</subfield></datafield><datafield tag="700" ind1="1" ind2=" "><subfield code="a">Dettmer, H. William</subfield><subfield code="e">Verfasser</subfield><subfield code="4">aut</subfield></datafield><datafield tag="856" ind1="4" ind2="2"><subfield code="m">HBZ Datenaustausch</subfield><subfield code="q">application/pdf</subfield><subfield code="u">http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=027609793&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA</subfield><subfield code="3">Inhaltsverzeichnis</subfield></datafield><datafield tag="999" ind1=" " ind2=" "><subfield code="a">oai:aleph.bib-bvb.de:BVB01-027609793</subfield></datafield></record></collection> |
| id | DE-604.BV042170355 |
| illustrated | Illustrated |
| indexdate | 2024-08-01T11:28:30Z |
| institution | BVB |
| isbn | 1574442937 9781574442939 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-027609793 |
| oclc_num | 898203829 |
| open_access_boolean | |
| owner | DE-862 DE-BY-FWS |
| owner_facet | DE-862 DE-BY-FWS |
| physical | XXVIII, 342 S. Ill., graph. Darst. |
| publishDate | 2001 |
| publishDateSearch | 2001 |
| publishDateSort | 2001 |
| publisher | St. Lucie Press [u.a.] |
| record_format | marc |
| series2 | TheCRC press series on constraints management |
| spellingShingle | Schragenheim, Eli Dettmer, H. William Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope |
| title | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope |
| title_auth | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope |
| title_exact_search | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope |
| title_full | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope Eli Schragenheim ; H. William Dettmer |
| title_fullStr | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope Eli Schragenheim ; H. William Dettmer |
| title_full_unstemmed | Manufacturing at warp speed optimizing supply chain financial performance ; includes simplified drum-buffer-rope Eli Schragenheim ; H. William Dettmer |
| title_short | Manufacturing at warp speed |
| title_sort | manufacturing at warp speed optimizing supply chain financial performance includes simplified drum buffer rope |
| title_sub | optimizing supply chain financial performance ; includes simplified drum-buffer-rope |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=027609793&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT schragenheimeli manufacturingatwarpspeedoptimizingsupplychainfinancialperformanceincludessimplifieddrumbufferrope AT dettmerhwilliam manufacturingatwarpspeedoptimizingsupplychainfinancialperformanceincludessimplifieddrumbufferrope |
Inhaltsverzeichnis
THWS Schweinfurt Zentralbibliothek Lesesaal
| Signatur: |
2000 QP 500 S377 |
|---|---|
| Exemplar 1 | ausleihbar Verfügbar Bestellen |
| Exemplar 2 | ausleihbar Verfügbar Bestellen |