New Manufacturing Challenge: Techniques for Continuous Improvement

New Manufacturing Challenge: Techniques for Continuous Improvement
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The best introduction to lean

The Classic that transcended the time

Continuous Improvement Principles

And still we have more Japanese authors leaching on to varia

5 stars plus

New Manufacturing Challenge: Techniques for Continuous Improvement
Kiyoshi Suzaki
Manufacturer: Free Press
ProductGroup: Book
Binding: Hardcover

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Production, Operation & Management | Industrial, Manufacturing & Operational Systems | Engineering | Professional & Technical | Subjects | Books
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New Shop Floor Management: Empowering People for Continuous Improvement

Lean Thinking : Banish Waste and Create Wealth in Your Corporation, Revised and Updated

The Toyota Way

The Machine That Changed the World : The Story of Lean Production

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ASIN: 0029320402

Book Description

As a consultant, Kiyoshi Suzaki has helped scores of Fortune 500 clients improve manufacturing operations and get the job done faster, cheaper, better, and safer. Now, in this detailed "operating manual" -- full of more step-by-step applications than any other book available -- Suzaki spells out new options in production and employee resources that can help American industry regain the cutting edge in price, quality, and delivery of products.

A well-known expert in the field, Suzaki begins with the premise that "if it doesn't add value, it's waste" -- a concept devised by Henry Ford and later used by Toyota. He recaps what Toyota identifies as the seven most prominent forms of waste in factories. Most importantly, he meticulously details steps individuals can take to "simplify, combine, and eliminate operations" -- thereby reducing waste, improving quality, and saving money.

Describing in detail the basic techniques culled from Japanese industrial philosophy and procedure, Suzaki shows how small, family-run businesses and billion-dollar American corporations from a wide range of industries -- automotive, electronics, cosmetics, and even defense contractors -- are meeting the manufacturing challenge today -- demolishing the widely held belief that most American manufacturers have become distribution organizations for products manufactured overseas. In addition, he links his methodology with several successful production systems, from Just-In-Time Production, Total Quality Control, Total Productive Maintenance to Computer Integrated Manufacturing. Throughout this practical handbook, he places emphasis squarely on the shop floor and grounds his approach in easy, yet powerful techniques everybody can understand and implement today.

Illustrated with numerous charts and exhibits, The New Manufacturing Challenge shows how to integrate people and techniques to improve the workplace and, thus, strengthen any company's competitiveness in the global marketplace.

Customer Reviews:

The best introduction to lean.......2004-11-22

Suzaki's book, like the other introductory texts, describes the operations of factories practicing JIT/lean production, but not how to convert a traditional plant. It describes the destination but not the way to get there. This is appropriate for readers who are new to the subject, and Suzaki writes well enough to retain a manager's attention during air travel.

The Classic that transcended the time.......2003-08-19

I still go back to this now a classic to get the sense out of it. There are many techniques, ideas, but more importantly, it points the appreciation of people engaged in the process of continuous improvement as a core to drive us to move forward. Whatever way people may call this stuff, the person who discovered the principle of improvement cannot but to move on in his life for the betterment.

By the way, there is a 3.5hour video correponding to this book still available at SME (Society of Manufacturing Engineers). Read the book, share the examples, confirm the principle, practice the heartbeat of improvement, and keep on moving forward.

Good luck!

Continuous Improvement Principles.......2002-05-23

This is an easy read book with some excellent ideas. Highly recommended for anyone wanting to improve something. The ideas can be used also in service and general life -- although primarily aimed at manufacturing.

And still we have more Japanese authors leaching on to varia.......2001-09-30

This book could have been written by taking exerps from other books on TPS and rearranging the pages. Same old, same old more same old.
We need an American's view on the practicle application of TPS not advice from some guy from Japan who doesn't have the faintest idea of American culture or people. So there!

5 stars plus.......2001-05-17

This is THE book for hands-on actual implementation of lean production techniques. This book answers the difficult problems accompaning implementation of the Toyota Production System. It is written in an easily understood straight-forward style. In my opinion this is the best book on boosting shopfloor efficiency. It does not shy away from discussing the problem areas. The author proves he has "been there and done it". An example is the Kanban system usually described in most books as a sytem where cards control the shop floor work flow. This book describes in detail various Kanban systems to handle the situations where the work flow is interrupted by processes requiring outside vendors or where an operation such as heat treating will slow the process. I rated this book five stars because it discusses real problems and solutions.

Lean Enterprise Systems: Using IT for Continuous Improvement

Average customer rating:

A serious read for the manufacturing IT professional...

Lean Enterprise Systems: Using IT for Continuous Improvement
Steve Bell
Manufacturer: Wiley-Interscience
ProductGroup: Book
Binding: Hardcover

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Similar Items:

Lean Manufacturing: A Plant Floor Guide
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The Resilient Enterprise: Overcoming Vulnerability for Competitive Advantage
Practical Lean Accounting: A Proven System for Measuring and Managing the Lean Enterprise

ASIN: 0471677841

Book Description

Learn how Lean IT can help companies deliver better customer service and value

Lean Enterprise Systems effectively demonstrates how the techniques derived from Lean Manufacturing, combined with the thoughtful application of information technology, can help all enterprises improve business performance and add significant value for their customers. The author also demonstrates how the basic concepts of Lean Manufacturing can be applied to create agile and responsive Lean IT.

The book is divided into three parts that collectively explore how people, processes, and technology combine forces to facilitate continuous improvement:
* Part One: Building Blocks of the Lean Enterprise sets forth the essentials of Lean. Readers discover where, when, and how Lean IT adds substantial value to the Lean Enterprise through integrated processes of planning, scheduling, execution, control, and decision making across the full spectrum of operations.
* Part Two: Building Blocks of Information Systems explores the primary components of an enterprise information system and how these components may be integrated to improve the flow of information supporting value streams. Readers learn how information systems help organize and deliver knowledge when and where it's needed.
* Part Three: Managing Change with IT demonstrates how the skillful combination of process and information technology improvements empowers people to continuously improve the Lean Enterprise. Readers develop the skills to exploit emerging information technology tools and change management methods, crafting a Lean IT framework-reducing waste, complexity, and lead time-while adding measurable value.

Executives, managers, and improvement teams across a broad range of industries, as well as IT professionals, can apply the techniques described in this publication to improve performance, add value, and create competitive advantage. The book's clear style and practical focus also makes it an excellent textbook for upper-level undergraduate and graduate courses in business, operations management, and business information systems.

Download Description

The forces of Lean and Information Technology are complementary. Moreover, the transformation of any enterprise to a competitive Lean enterprise requires the skillful use of IT throughout the internal value streams and external supply chain. This book uses the lessons learned from 50 years of Lean, which began with the Toyota Production System, along with Six Sigma and Theory of Constraints, to clearly describe a comprehensive framework for how IT can support the continuous improvement of manufacturing and non-manufacturing companies. The author also applies the fundamentals of Lean Manufacturing to the evolution of Lean IT.

Customer Reviews:

A serious read for the manufacturing IT professional..........2006-09-10

If you're involved in a manufacturing organization's IT department, this particular book will provide you with a lot of information about manufacturing theory and practice, as well as how IT plays a part in it all... Lean Enterprise Systems: Using IT for Continuous Improvement by Steve Bell.

Part 1 - Building Blocks of the Lean Enterprise: Lean and IT - the Human Factor; Realizing the Value of Lean; Three Stages of Lean Evolution; Fundamentals of Production and Inventory Management; Lean Planning and Execution
Part 2 - Building Blocks of Information Systems: Charting the Enterprise Software Universe; Integrating the Value Streams; Managing Knowledge for Competitive Advantage
Part 3 - Managing Change with IT: The Event-Driven Lean Enterprise; Linking Strategy with Action - Performance Management; Lean IT - Applying Continuous Improvement to Information Systems; Postscript - Zen and the Art of Lean
Acknowledgements; Acronyms; Endnotes; Index

This is one of those books that is extremely dense with information, but is admittedly beyond my experience level. Bell goes into great depth on how manufacturing production cycles function (or don't function) both in theory and reality. A prior background or some level of knowledge of how the Japanese manufacturing techniques work is helpful, as you'll see terms like kanban and kaizen used frequently. The goal is to use IT systems to help drive the process towards a "lean" approach, or one that is light on inventory and strong in "just-in-time" scheduling. While not an easy read by any stretch, the material is such that it could be considered a "should be on the bookshelf" item for any IT professional who considers themselves a subject expert in manufacturing.

Activity-Based Management: A Comprehensive Implementation Guide

Average customer rating:

Excellent!
activity base management

Activity-Based Management: A Comprehensive Implementation Guide
Edward Forrest
Manufacturer: McGraw-Hill
ProductGroup: Book
Binding: Hardcover

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Implementing Activity-Based Management in Daily Operations (Nam/Wiley Series in Manufacturing)
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ASIN: 007021588X

Book Description

Easy Activity-Based Management Implementation. Everyone's touting activity-based management (ABM) as the best costing method for reengineering and TQM inititatives. But where do you begin? Edward Forrest's groundbreaking Activity-Based Management: A Comprehensive Implementation Guide. This exhaustive guide takes you step-by-step through each stage of planning, organizing, implementing, and managing your own ABM program to support continuous improvement, boost profits, and eliminate non-value added activities. You get expert guidance on everything from streamlining data collection and analysis to using the results to boost ROI. You even get all the ready-to-use forms, reports, and procedures you need to facilitate and measure your program's progress.

Customer Reviews:

Excellent!.......2005-03-12

Seller was very professional and honest. I received the book in perfect conditions and before the estimated time.

activity base management.......2000-02-25

very good and comprehensive book with up to date informatio

Process Improvement in Quality Management Systems: A case study analyzing Carnegie Mellon's Capability Maturity Model (CMM)

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Process Improvement in Quality Management Systems: A case study analyzing Carnegie Mellon's Capability Maturity Model (CMM)
Dr. Walter R. McCollum
Manufacturer: Trafford Publishing
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Binding: Paperback

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ASIN: 141203650X
Release Date: 2006-07-06

Product Description

A tool for senior managers, program managers, project managers, and decision makers in their effort to establish organizational responsibility for software process activities, and to improve process performance across organizations.

Esd Program Management: A Realistic Approach to Continuous Measurable Improvement in Static Control (The International Series in Engineering and Computer Science)

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Esd Program Management: A Realistic Approach to Continuous Measurable Improvement in Static Control (The International Series in Engineering and Computer Science)
G. Theodore Dangelmayer
Manufacturer: Springer
ProductGroup: Book
Binding: Hardcover

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ASIN: 0412136716

Book Description

This is a revision of the highly successful electronic manufacturing guide, ESD Program Management: A Realistic Approach to Continuous Measurable Improvement in Static Control. This revision is comprehensive and explains how to develop, implement and manage an ESD control program, and includes up-to-date data, many new chapters, new case studies, and much more. New to this edition: Extensive changes and additions to auditing techniques, cost benefits data, and materials evaluation. Six new chapters on common myths, issues related to smaller companies, process controls, ISO 9000, material characterization, and training. New case studies on field-induced failures in the factory, long-distance central office system upsets, and automation-caused failures. Expanded coverage of the needs of smaller companies including discussion of common problems and cost-effective solutions. A training breakthrough is presented. Previously invisible ESD events can now be easily displayed for students at all levels - `Seeing is believing!' Inclusion of new testing instruments such as the event detector and resistance probe. The 12 critical factors in an ESD program have been updated to reflect changes and refinements in program management. The author has also included the latest information on handling procedures and requirements from the Lucent ESD Control Handbook. ESD Program Management: A Realistic Approach to Continuous Measurable Improvement in Static Control, Second Edition, is a refreshingly unbiased guide for electronic manufacturing and quality control professionals.

Average customer rating:

Goes straight to the heart of CPI

Continuous Process Improvement
George D. Robson
Manufacturer: Free Press
ProductGroup: Book
Binding: Hardcover

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The Goal

ASIN: 0029266459

Book Description

During the past decade Japanese companies have derived many of their competitive advantages from streamlined work-flow processes. Desperate to replicate the Japanese systems, American managers have bought into countless theories advanced by management consultants which, lacking a methodology, have proved fruitless and frustrating. Now, from inside a world-renowned learning organization, comes that methodology.

Continuous Process Improvement (CPI) is an improvement and problem-prevention system created and developed by George Robson to "empower" natural work teams in three General Electric businesses. Composed of a logical set of steps, at the heart of which is "Process Flow Diagramming," CPI focuses on and simplifies the critical elements of work flow processes and eliminates those parts that add no value.

Not only has this methodology helped these GE businesses save in excess of $35 million during the first two years of implementation, but similar techniques are now being employed by leading-edge companies throughout the world. CPI is a transportable system that not only has profoundly changed manufacturing practices, but has been applied with equal success in all areas of a business. Robson shows how the "Iceberg Phenomenon" can identify the measurable benefits of accurately accounting for direct and indirect costs by carefully tracking expenses. Planning for the true costs of customer service, marketing concessions, and retraining can turn unplanned losses into short- and long-term returns on investments. Robson focuses on activities that are critical to quality in design and production and demonstrates how non-value-added work can be eliminated. The staggering cost of re-work, calculated in "The Rule of Tens," is reduced by catching mistakes before they escape to subsequent stages of handling. The CPI system, which has been widely praised within General Electric, will be of broad interest throughout the business and university communities.

Customer Reviews:

Goes straight to the heart of CPI.......2002-07-03

You can buy any number of books on continuous improvement or process design and become quickly mired in overwhelming detail. This book, on the other hand, goes to the heart of what a process is, the true meaning of 'continuous process improvement' (a frequently misused term in my opinion), and the steps needed to achieve it.

Chapter 1 starts by explaining continuous process improvement, its business benefits, and some simple tools that will get you started. This chapter is so well written and makes so much sense that if this were a novel it would be considered to be a 'grabber'. The next two chapters get you started by showing you how to map and evaluate a process.

I like the way you are quickly led to focus on what's important through problem statement and analysis. Chapter 4 introduces the real tools for continuous improvement - statistical process control charts - and manages to cover this daunting topic without losing the reader. This is no mean feat because the material isn't simple in nature. The treatment is brief and will probably raise more questions if you are not familiar with statistical process controls. If that's the case you will probably want to read "SPC Simplified: Practical Steps to Quality" by Robert T. Amsden (or if you are in the service industry, "SPC Simplified for Services" by Davida M. Amsden, which is the same boom with an emphasis on services). The final chapter wraps up by giving advice about implementing corrective action, project management considerations, and managing teams and meetings.

This is the best introduction to continuous process improvement, in my opinion, and one that I recommend highly to anyone who is new to the subject. I also recommend "Solve That Problem!: Readymade Tools for Continuous Improvement" by Steve Smith (ISBN 0749424826), which expands on the basic CPI tools that this book introduces.

Quality and Productivity in the Graphic Arts: How to Improve Quality, Productivity, and Profit Utilizing a Continuous Quality Improvement Program and Statistical Process Control (Spc
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Quality and Productivity in the Graphic Arts: How to Improve Quality, Productivity, and Profit Utilizing a Continuous Quality Improvement Program and Statistical Process Control (Spc
Miles Southworth , and Donna Southworth
Manufacturer: Graphic Arts Center Publishing Company
ProductGroup: Book
Binding: Hardcover

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ASIN: 0933600054

Analyzing variability in continuous processes [An article from: European Journal of Operational Research]
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Analyzing variability in continuous processes [An article from: European Journal of Operational Research]
K. Rajaram , and A. Robotis
Manufacturer: Elsevier
ProductGroup: Book
Binding: Digital

Elsevier | By Publisher | e-Docs | Formats | Books
ASIN: B000RR0V0U

Book Description

This digital document is a journal article from European Journal of Operational Research, published by Elsevier in 2004. The article is delivered in HTML format and is available in your Amazon.com Media Library immediately after purchase. You can view it with any web browser.

Description:
We analyze the impact of variability on a continuous flow production process. To perform this analysis, we consider an n-stage, serial continuous process in which variability is introduced at each stage. We develop a continuous time model to capture the propagation of variability through the system and use this model to calculate the mean and the variance of the distribution of the output from this process. These results are then used to determine the optimal decisions for variability reduction when designing and operating these processes.

Benchmarking the injection molding process for continuous improvement.: An article from: Plastics Engineering

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Benchmarking the injection molding process for continuous improvement.: An article from: Plastics Engineering
Anne Bernhardt , and Natalia Kassa
Manufacturer: Society of Plastics Engineers, Inc.
ProductGroup: Book
Binding: Digital

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Book Description

This digital document is an article from Plastics Engineering, published by Society of Plastics Engineers, Inc. on February 1, 1996. The length of the article is 2433 words. The page length shown above is based on a typical 300-word page. The article is delivered in HTML format and is available in your Amazon.com Digital Locker immediately after purchase. You can view it with any web browser.

Citation Details
Title: Benchmarking the injection molding process for continuous improvement.
Author: Anne Bernhardt
Publication: Plastics Engineering (Refereed)
Date: February 1, 1996
Publisher: Society of Plastics Engineers, Inc.
Volume: v52 Issue: n2 Page: p31(3)

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Combining process knowledge for continuous quality improvement.: An article from: IIE Transactions

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Combining process knowledge for continuous quality improvement.: An article from: IIE Transactions
Xiaohe Liu , Kevin J. Dooley , and John C. Anderson
Manufacturer: Institute of Industrial Engineers, Inc. (IIE)
ProductGroup: Book
Binding: Digital

General | Business & Investing | Subjects | Books

Book Description

This digital document is an article from IIE Transactions, published by Institute of Industrial Engineers, Inc. (IIE) on December 1, 1995. The length of the article is 6419 words. The page length shown above is based on a typical 300-word page. The article is delivered in HTML format and is available in your Amazon.com Digital Locker immediately after purchase. You can view it with any web browser.

Citation Details
Title: Combining process knowledge for continuous quality improvement.
Author: Xiaohe Liu
Publication: IIE Transactions (Refereed)
Date: December 1, 1995
Publisher: Institute of Industrial Engineers, Inc. (IIE)
Volume: v27 Issue: n6 Page: p811(9)

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