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Improving Production with Lean Thinking

Book Description

Unique coverage of manufacturing management techniques--complete with cases and real-world examples.

Improving Production with Lean Thinking picks up where other references on production processes leave off. It is increasingly important to integrate and systematize lean thinking throughout production/manufacturing and the supply chain because the market is becoming more competitive, products are becoming more complex, and product life is getting shorter and shorter. With a practical focus, this book encompasses the science and analytical background for improving manufacturing, control, and design. It covers specific methodologies and tools for:

  • Material flow and facilities layout, including a six step layout design process

  • The design of cellular layouts

  • Analyzing and improving equipment efficiency, including Poka-Yoke, motion study, maintenance, SMED, and more

  • Environmental improvements, including 5S implementation

  • With real-life case studies of successful European and American approaches to lean manufacturing, this reference is ideal for engineers, managers, and researchers in manufacturing and production facilities as well as students. It bridges the gap between production/manufacturing and supply chain techniques and provides a detailed roadmap to improved factory performance.

    Table of Contents

    1. Cover Page
    2. Title Page
    3. Copyright
    4. Contents
    5. Preface
    6. 1: Continuous Improvement Tools
      1. CONTINUOUS IMPROVEMENT
      2. IMPROVEMENT PHILOSOPHIES AND METHODOLOGIES
      3. JUST-IN-TIME (JIT)
      4. MEASURING AND PRIORITIZING THE IMPROVEMENTS
      5. BOOK STRUCTURE
      6. RECOMMENDED READINGS
    7. 2: Material Flow and Facilities Layout
      1. LAYOUT IMPROVEMENTS
      2. THEORETICAL BASIS
      3. LAYOUT DESIGN METHODOLOGY
      4. TOOLS FOR LAYOUT STUDY
      5. SUMMARY
      6. RECOMMENDED READINGS
    8. 3: Material Flow and the Design of Cellular Layouts
      1. THE ASSEMBLY LINE
      2. THEORETICAL BASIS
      3. CELL DESIGN METHODOLOGY
      4. CELL DESIGN TOOLS
      5. SUMMARY
      6. RECOMMENDED READINGS
    9. 4: Equipment Efficiency: Quality and Poka-Yoke
      1. THEORETICAL BASIS
      2. POKA-YOKE DESIGN METHODOLOGY
      3. SUMMARY
      4. RECOMMENDED READINGS
    10. 5: Equipment Efficiency: Performance and Motion Study
      1. MOTION STUDY
      2. THEORETICAL BASIS
      3. MOTION STUDY TOOLS
      4. SUMMARY
      5. RECOMMENDED READINGS
    11. 6: Equipment Efficiency: Availability, Performance, and Maintenance
      1. EQUIPMENT MAINTENANCE
      2. THEORETICAL BASIS
      3. MAINTENANCE PROGRAM IMPLEMENTATION
      4. MAINTENANCE TOOLS
      5. SUMMARY
      6. RECOMMENDED READINGS
    12. 7: Equipment Efficiency: Availability, Quality, and SMED
      1. SETUP PROCESS
      2. THEORETICAL BASIS
      3. SMED METHODOLOGY
      4. SMED TOOLS
      5. SMED EFFECTS AND BENEFITS
      6. SUMMARY
      7. RECOMMENDED READINGS
    13. 8: Environmental Improvements and the 5S Methodology
      1. A CLEAN AND ORGANIZED WORKSPACE
      2. 5S IMPLEMENTATION METHODOLOGY
      3. IMPLEMENTATION OF THE 5S METHODOLOGY IN OFFICES
      4. 5S TOOLS
      5. 5S BENEFITS AND EFFECTS
      6. SUMMARY
      7. RECOMMENDED READINGS
    14. 9: Other Improvement Keys
      1. HUMAN RESOURCES–RELATED KEYS
      2. Improvement Team Activities
      3. EFFICIENT MATERIALS USE–RELATED KEYS
      4. VISUAL CONTROL–RELATED KEYS
      5. TECHNOLOGY–RELATED KEYS
      6. SUMMARY
      7. RECOMMENDED READINGS
    15. Appendix A: Problems
      1. INTRODUCTION
      2. CONTINUOUS IMPROVEMENT TOOLS
      3. FACILITIES LAYOUT
      4. CELLULAR LAYOUT
      5. MAINTENANCE
      6. MOTION STUDY
      7. MACHINE-MACHINE DIAGRAMS
      8. NUMERIC PROBLEM SOLUTIONS
    16. Index