Improving Production With Lean Thinking

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.

JAVIER SANTOS and JOSE M. TORRES are professors in the Department of Engineering at the University of Navarra Technological Campus in San Sebastian, Spain.
RICHARD A. WYSK, PHD is the Leonhard Chair in Engineering, in the Department of Industrial and Manufacturing Engineering at Pennsylvania State University. He is the coauthor of the best selling college textbook Computer-Aided Manufacturing.

Preface.
Chapter 1. Continuous improvement tools.
Introduction.
Improvement philosophies and methodologies.
Just-in-time (JIT).
Thinking Revolution.
Lean Manufacturing.
20 Keys to workplace improvement.
Measuring and prioritizing the improvements.
Book Structure.
Recommended Readings.
Chapter 2. Material flow and facilities layout.
Introduction.
Signs and reasons for a need to change the layout.
Theoretical Bases.
One-piece flow.
Main types of industrial companies.
Layout types.
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.
Summary.
Advised Bibliography.
Chapter 3. Material flow and design of cellular layouts.
Introduction.
Theoretical basis.
Mass production.
Flow or assembly lines.
Cell layout design justification.
Basic cells design nomenclature.
Cell design methodology.
Cell design tools.
Line Balancing.
Group technology.
Time study.
Leveling production.
Multifunctional workers.
Workforce optimization.
Summary.
Recommended Readings.
Chapter 4. Equipment Efficiency: Quality and Poka-Yoke.
Introduction.
Theoretical Bases.
Inspection and SQC (Statistical Quality Control).
From SQC to Zero defects.
Poka-Yoke design methodology.
Poka-Yoke examples.
Summary.
Recommended Readings.
Chapter 5. Equipment Efficiency: Performance and Motion study.
Introduction.
Theoretical Bases.
Motion economy principles.
Motion study tools.
Value analysis.
5W2H and 5-Why methods.
Worker-machine diagram.
Machine-worker ratio.
Machine-machine diagram.
Summary.
Recommended Readings.
Chapter 6. Equipment Efficiency: Availability, performance and maintenance.
Introduction.
Theoretical Bases.
Types of maintenance.
Maintenance program implementation.
Getting started.
Corrective maintenance implementation.
Preventive maintenance implementation.
Autonomous maintenance.
TPM - Total Productive Maintenance.
RCM - Reliability Centered Maintenance.
Maintenance tools.
FMEA for equipment.
Reliability.
P-M Analysis.
Maintenance management.
Summary.
Recommended Readings.
Chapter 7. Equipment Efficiency: Availability, quality and SMED.
Introduction.
Theoretical Bases.
Basic steps in a set-up process.
Traditional strategies to improve the set-up process.
SMED methodology.
Preliminary stage.
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.
SMED tools.
First stage tools.
Second stage tools.
Third stage tools.
Zero changeover.
SMED effects and benefits.
Easier set-up process.
On-hand stock production.
Workplace tasks simplification.
Productivity and flexibility.
Economic benefits.
Summary.
Recommended Readings.
Chapter 8. Environment Improvements and The 5S.
Introduction.
5S implementation methodology.
Getting started.
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 tools.
Red-tagging strategy.
Sign strategy.
Painting strategy.
Preventive order.
Preventive shine.
Promotion tools.
5S Benefits and effects.
Summary.
Recommended Readings.
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.
Reducing inventory.
Visual control related keys.
Andon.
Kanban.
Technology related keys.
Jidoka.
Using information systems.
Leading technology and site technology.
Summary.
Recommended Readings.
Appendix A: Numeric problems.
Continuous improvement tools.
Facilities Layout.
Cellular Layout.
Maintenance.
Motion Study.
Machine-Machine diagram.