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.
Chapter 1. Continuous improvement tools.
Improvement philosophies and methodologies.
20 Keys to workplace improvement.
Measuring and prioritizing the improvements.
Chapter 2. Material flow and facilities layout.
Signs and reasons for a need to change the layout.
Main types of industrial companies.
Characteristic of the traditional layouts.
Layout design methodology.
Step 1. Formulate the problem.
Step 2. Analysis of the problem.
Step 3. Search for alternatives.
Step 4. Choose the right solution.
Step 5. Specification of the solution.
Step 6. Design cycle.
Tools for layout study.
Muther's 8 factors.
Chapter 3. Material flow and design of cellular layouts.
Flow or assembly lines.
Cell layout design justification.
Basic cells design nomenclature.
Cell design methodology.
Cell design tools.
Chapter 4. Equipment Efficiency: Quality and Poka-Yoke.
Inspection and SQC (Statistical Quality Control).
From SQC to Zero defects.
Poka-Yoke design methodology.
Chapter 5. Equipment Efficiency: Performance and Motion study.
Motion economy principles.
Motion study tools.
5W2H and 5-Why methods.
Chapter 6. Equipment Efficiency: Availability, performance and maintenance.
Types of maintenance.
Maintenance program implementation.
Corrective maintenance implementation.
Preventive maintenance implementation.
TPM - Total Productive Maintenance.
RCM - Reliability Centered Maintenance.
FMEA for equipment.
Chapter 7. Equipment Efficiency: Availability, quality and SMED.
Basic steps in a set-up process.
Traditional strategies to improve the set-up process.
Stage 1. Separating internal and external set-up.
Stage 2. Converting internal set-up to external set-up.
Stage 3. Streamlining all aspects of the set-up process.
First stage tools.
Second stage tools.
Third stage tools.
SMED effects and benefits.
Easier set-up process.
On-hand stock production.
Workplace tasks simplification.
Productivity and flexibility.
Chapter 8. Environment Improvements and The 5S.
5S implementation methodology.
Common steps in the five pillars.
First pillar: Sort.
Second pillar: Set in order.
Third pillar: Shine.
Fourth pillar: Standardize.
Fifth pillar: Sustain.
Implementation of the 5S in offices.
5S apply to computers.
5S Benefits and effects.
Chapter 9. Other improvement keys.
Human resources related keys.
Rationalizing the system.
Improvement team activities.
Empowering workers to make improvements.
Efficient materials use related keys.
Developing your suppliers.
Conserving energy and materials.
Visual control related keys.
Technology related keys.
Using information systems.
Leading technology and site technology.
Appendix A: Numeric problems.
Continuous improvement tools.