Improving Production with Lean Thinking E-Book

Javier Santos

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 301

Veröffentlichungsjahr: 2015

Beschreibung

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.

Leseprobe

Contents

Cover

Contents

Title Page

Copyright

Preface

1: Continuous Improvement Tools

CONTINUOUS IMPROVEMENT

IMPROVEMENT PHILOSOPHIES AND METHODOLOGIES

JUST-IN-TIME (JIT)

MEASURING AND PRIORITIZING THE IMPROVEMENTS

BOOK STRUCTURE

RECOMMENDED READINGS

2: Material Flow and Facilities Layout

LAYOUT IMPROVEMENTS

THEORETICAL BASIS

LAYOUT DESIGN METHODOLOGY

TOOLS FOR LAYOUT STUDY

SUMMARY

RECOMMENDED READINGS

3: Material Flow and the Design of Cellular Layouts

THE ASSEMBLY LINE

THEORETICAL BASIS

CELL DESIGN METHODOLOGY

CELL DESIGN TOOLS

SUMMARY

RECOMMENDED READINGS

4: Equipment Efficiency: Quality and Poka-Yoke

POKA-YOKES

THEORETICAL BASIS

POKA-YOKE DESIGN METHODOLOGY

SUMMARY

RECOMMENDED READINGS

5: Equipment Efficiency: Performance and Motion Study

MOTION STUDY

THEORETICAL BASIS

MOTION STUDY TOOLS

SUMMARY

RECOMMENDED READINGS

6: Equipment Efficiency: Availability, Performance, and Maintenance

EQUIPMENT MAINTENANCE

THEORETICAL BASIS

MAINTENANCE PROGRAM IMPLEMENTATION

MAINTENANCE TOOLS

SUMMARY

RECOMMENDED READINGS

7: Equipment Efficiency: Availability, Quality, and SMED

SETUP PROCESS

THEORETICAL BASIS

SMED METHODOLOGY

SMED TOOLS

SMED EFFECTS AND BENEFITS

SUMMARY

RECOMMENDED READINGS

8: Environmental Improvements and the 5S Methodology

A CLEAN AND ORGANIZED WORKSPACE

5S IMPLEMENTATION METHODOLOGY

IMPLEMENTATION OF THE 5S METHODOLOGY IN OFFICES

5S TOOLS

5S BENEFITS AND EFFECTS

SUMMARY

RECOMMENDED READINGS

9: Other Improvement Keys

HUMAN RESOURCES–RELATED KEYS

EFFICIENT MATERIALS USE-RELATED KEYS

VISUAL CONTROL-RELATED KEYS

TECHNOLOGY-RELATED KEYS

SUMMARY

RECOMMENDED READINGS

Appendix A: Problems

INTRODUCTION

CONTINUOUS IMPROVEMENT TOOLS

FACILITIES LAYOUT

CELLULAR LAYOUT

MAINTENANCE

MOTION STUDY

MACHINE-MACHINE DIAGRAMS

NUMERIC PROBLEM SOLUTIONS

Index

Wiley End User License Agreement

List of Tables

2: Material Flow and Facilities Layout

TABLE 2.1. Main Characteristics of the Three Traditional Layouts

3: Material Flow and the Design of Cellular Layouts

TABLE 3.1. Previous and Current Economic Environments

TABLE 3.2. Most Common Activity Scales

7: Equipment Efficiency: Availability, Quality, and SMED

TABLE 7.1. Effect of Setup Time on Production Time

TABLE 7.2. Effect of Large Setup Time in Production Time

TABLE 7.3. Effect of Short Setup Time in Product Cost

TABLE 7.4. Initial Situation

TABLE 7.5. Task Sharing and Simultaneous Operations

TABLE 7.6. Improvement in Task Sharing

List of Illustrations

1: Continuous Improvement Tools

Figure 1.1. The concept of continuous improvement versus reengineering.

Figure 1.2. Continuous change can offset the expense and time required for radical changes.

Figure 1.3. Resources that must be managed effectively.

Figure 1.4. Just-in-time thinking principles. Reprinted with permission from

20 Keys to Workplace Improvement

. English translation copyright © 1995 by Productivity Press, a division of Kraus Productivity Ltd., Translated by Bruce Talbot. Appendix A translated by Miho Matsubara. Appendix C translated by Warren Smith. www.productivitypress.com.

Figure 1.5. Inventory can hide production inefficiencies and slow improvements.

Figure 1.6. Saving time means eliminating waste.

Figure 1.7. The 20 keys to workplace improvement. Reprinted with permission from

JIT Factory Revolution:

A pictorial guide to factory design of the future. English translation copyright © 1988 by Productivity Press a division of Kraus Productivity. Ltd. www.productivitypress.com.

Figure 1.8. Assessing the current position (level) and the target position is critical to success.

Figure 1.9. Radar graphic for each factor.

Figure 1.10. Typical planning times used for production.

Figure 1.11. Grouping losses (waste) to obtain the useful time.

Figure 1.12. Measuring losses in a system.

Figure 1.13. Different consequences of an improvement in maintenance.