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Books > Professional & Technical > Industrial chemistry & manufacturing technologies > Other manufacturing technologies > General
What is a learning organization? What are the advantages of creating one? Why should a company want to become a learning organization? Where does one start? Learning Organizations: Developing Cultures for Tomorrow's Workplace contains essays by thirty-nine of the most respected practitioners and scholars of this topic. This definitive collection of essays is rich in concept and theory as well as application and example. Lead authors include Harvard's Rosabeth Moss Kanter, London Business School's Professor Emeritus Charles Handy, and MlT's Fred Kofman and Peter Senge. The thirty-two essays in this comprehensive collection are presented in four main parts: 1. Guiding Ideas 2. Theories/Methods/Processes 3. Infrastructure 4. Arenas of Practice
Applying lean to the supply chain is a hot topic. While lean operations can produce significant benefits to an organization, the greatest benefits will not be realized unless lean is extended beyond the organization to involve both suppliers and customers. Lean Supply Chain: Collected Practices and Cases provides a variety of case studies taken from articles previously published in "Lean Manufacturing Advisor" -- the monthly newsletter by Productivity Press.
Equipment downtime can bring a lean manufacturing operation to a complete standstill. Total productive maintenance (TPM) is such a fundamental part of becoming lean because a machine failure at one step of a continuous flow process will halt all the steps before and after it. Strategies aimed at eliminating downtime are essential in any operation in which the processes require the use of complex machinery and equipment. TPM: Collected Practices and Cases provides a variety of case studies taken from articles previously published in "Lean Manufacturer Advisor": the monthly newsletter by Productivity Press.
This comprehensive book presents a methodology for continuous process improvement in a structured, logical, and easily understandable framework based on industry accepted tools, techniques, and practices. It begins by explaining the conditions necessary for establishing a stable and capable process and the actions required to maintain process control, while setting the stage for sustainable efficiency improvements driven by waste elimination and process flow enhancement. This structured approach makes a clear connection between the need for a quality process to serve as the foundation for incremental efficiency improvements. This book moves beyond talking about the value contribution of tools and techniques for process control and continuous improvement by focusing on the daily work routines necessary to maintain and sustain these activities as part of a lean process and management mindset. Part 1 discusses process quality improvement with an understanding of variation and its impact on process performance. It continues by stressing the importance of standardizing a process to achieve process stability. Once process stability is reflected in a consistent and predictable output, attention is turned to ensuring the process is capable of consistently meeting customer requirements. This series of activities sets the foundation for process control and the sustainable pursuit of efficiency improvements. Part 2 focuses on efficiency improvement by eliminating waste while improving process flow using proven tools and methods. Although there is a clear relationship between waste elimination and process flow, these activities are discussed separately to allow those more interested in waste elimination to work independently from those looking to optimize value stream flow. Part 3 explores the principles, practices, systems, and behaviors required to maintain process control while creating a mindset of continuous incremental improvement. It considers the role organizational structure, discipline, and accountability play as essential components for long term operational success. This book will: Provide readers with a clear roadmap for establishing, achieving, and maintaining process control as the foundation upon which to pursue efficiency improvements. Establish direction and methods for continuous and sustainable process improvement Define the practices, systems, and behaviors required to realize desired results and develop a culture of process control and continuous improvement along the road to operational excellence.
By reconfiguring your traditional assembly lines into production cells based on one-piece flow, you can drastically reduce your lead time, staffing requirements, and number of defects. Kenichi Sekine studied under the late Shigeo Shingo and is responsible for many recent advances in the deployment of the Toyota Production System in Japan. In this comprehensive book, Sekine provides an in-depth education into the why's and how's of the restructuring process. Sekine first examines the basic principles of process flow building, then offers detailed case studies of how various industries designed unique one-piece flow systems (parallel, L-shaped, and U-shaped floor plans) to meet their particular needs. One-Piece Flow describes each step in the process of establishing one-piece flow and: (1) provides ample "test your skills" worksheets that guide you through the solution of problems, and (2) includes over 300 illustrations and 14 single-page case studies that show how to cut assembly personnel in various industries. With this book, plant managers will learn how to eliminate overstaffing waste and build a multi-skilled work force equipped to support JIT manufacturing. The book includes:
The Lean Office: Collected Practices and Cases is a compilation of articles previously published in the Productivity Press newsletter, Lean Manufacturing Advisor. These articles discuss lean implementations in non-manufacturing operations, from design to processing invoices to customer service. Most articles are written in the form of case studies. Highlights include- Practical, in-depth description of lean implementation, written in a conversational, easy-to-read style A large quantity of case studies unavailable from any other single source Responds to your desire for real-world lean office information
In this large-format implementation manual, TPM experts explain P-M Analysis. (A methodology that makes zero losses a reality in your TPM program.) P-M Analysis is designed to help your TPM teams analyze and eliminate chronic problems that have been neglected or unresolved in the past. Chronic quality defects and other chronic losses are hard to eradicate, because they typically have multiple, interrelated causes that vary with every occurrence. Common improvement strategies, like cause-and-effect analysis, are usually ineffective in dealing with such complex problems. P-M Analysis was specially developed to overcome the weaknesses of traditional methods. It offers a rigorous 8-step method for ensuring that all possible factors are identified and investigated. Through P-M Analysis, teams really get in touch with their equipment. Its unique skill-building process improves technological know-how while delivering solutions to persistent problems. The first four steps of this rigorous 8-step program help teams isolate and understand the root causes of defects and failures within main equipment mechanisms and peripheral systems. The final four steps provide a systematic approach for effectively controlling those causes. A critical concept in P-M Analysis is physical analysis -- a way of thinking about how defects and failures are generated that forces us to look at the physical principles involved and to quantify the changes in the relationship between the equipment mechanisms and product parts involved. When a proper physical analysis is carried out, teams are far less likely to overlook important factors or to waste time pursuing unrelated ones. Although not a cure-all, P-M Analysis has reduced chronic losses to zero and raised technological expertise in many manufacturing environments. This illustrated implementation manual provides a thorough step-by-step procedure for implementing P-M Analysis, along with practice exercises and graded examples. It is an unparalleled resource for anyone with a basic knowledge of TPM who is ready to fine-tune their loss-reduction activities. Here, finally, is a root-cause analysis method that will help teams achieve the ultimate goal of zero losses.
People with minimal math skills, and even those with advanced math skills, have difficulty grasping the intuitive concepts behind Statistical Process Control (SPC). Many practitioners do not understand the concepts behind Control Charts, the differences of out of control and out of specification, and the process variation on Control Charts. This book will explain these concepts by using a simple methodology that will bring a much greater level of understanding to those that use it by providing a detailed description of the method, using common language, real-world examples to illustrate the concept, and instructions on easy implementation.
Currently, the prime focus for US business plans should not be on the manufacturing process design and delivery processes, but on greatly improving innovation leadership, design engineering capability, and sales and marketing innovation. These three areas have been sadly lacking significant performance improvement during the past 20 years. The magic word for US business is "simplification." Most of the books written to date focus on the solution development aspect of the Innovation System Cycle, which is less than 15% of the total innovative system. Focusing on solution development is only the start -- the rest of the innovation system cycle is what turns an idea into a profitable business. The techniques in this book are directed at key tasks across the innovative process, such as maximizing quality, productivity, maintainability, usability, and reliability, while focusing on reducing the product cycle time and costs within the innovative process. This book uses more than 50 different approaches/concepts, which leads the reader in a very simple method for understanding, establishing, and effectively using an innovative system to provide a significant marketing advantage. Previous books have focused on what to do; however, this book focuses on how to do it. It transforms a complicated complex system into easy-to-use and understand methodology.
This book helps participants in agile software development environments learn to become leaders. Facilitative leaders should be at every level of the organization, from individual contributor to informal team leader to managers of all stripes -- it takes much focus and intentionality from senior organizational leaders, who have special obligations in creating successful lean and agile development environments. But, beyond the principles of facilitative leadership for agility, People over Process provides tips and demonstrative scenes for the more important and common software meetings: architecture simulations, project planning, team configurations, retrospectives, and more. The author fully illustrates the principles and shares proven techniques for the most important leadership events in agile projects. While this book focuses on facilitating extraordinarily well-prepared meetings, it serves as a metaphor for leadership more broadly. The leader's obligation to help their team make rigorous fact-based decisions; to gain broad input and have participants aligned on the outcomes and next steps; and to do so in an efficient way that respects the time of the participants is as relevant to every-day leadership activity as it is to conducting meetings. The author mixes background and explanation with demonstration -- in this case, the story of an agile project at the fictitious Pacifica Bank. The scenario constructed at Pacifica illustrates the concepts of effective leadership and productive workplace environments. The book concentrates on the flow of software from understanding what is needed through design, development, testing, and deployment. Essentially, the author provides a simple and powerful model of leadership, examples, and tips. This is not a cookbook on how to lead -- It is a set of principles and examples. All leaders must find their own way for their team, their organization, and their unique challenges.
Post-Capitalist Entrepreneurship: Startups for the 99% details the implications of the post-capitalist society on entrepreneurship around the globe, and it challenges many of our underlying assumptions about how entrepreneurs form startups and the objectives and roles, or lack thereof, of startup investors in a post-capitalist society. The author explores real emerging stories about different forms of post-capitalist entrepreneurship (PCE) with chapters dedicated to subjects such as platform cooperatives, alternative currencies (local, crypto, and time banking), and the emergence of blockchain-enabled Distributed Autonomous Organizations (DAOs). This book will help aspiring and current entrepreneurs, investors and policymakers to: Understand emerging trends in new forms of economic activity that will shape the future of entrepreneurial opportunities Discover new approaches to business modeling in the post venture-capital opportunity space Embrace Lean startup and collaborative startup approaches that can accelerate startups in these new markets Recognize new spaces and avoid being disintermediated by new forms of startups and financing Know why and how local governments should reshape entrepreneurship policy to support post-capitalist entrepreneurship for the 99%
"On Time-In Full" is an important work. Tim McLean provides an easy to follow practical approach to building a highly performing supply chain" -Drew Locher, Shingo Prize Winning Author and Lean Thinker The most fundamental requirement for a manufacturing or distribution business is to deliver to customers what they want, in the quantity they want, when they want it. It doesn't matter how good your product is, how much the customer likes your salesperson, how slick your marketing campaign is: If your customers can't get what they want when they want it, they will get it elsewhere, and your business will be in serious trouble. On Time in Full: Achieving Perfect Delivery with Lean Thinking in Purchasing, Supply Chain and Production Planning is a step-by-step practical guide to designing a Lean Supply Chain that will deliver what your customers need, when they need it, every time. Timothy McLean shares his three decades of Lean supply chain experience -- In simple straightforward language, he explores the reasons why supply chains fail to deliver and what you can do about it. On Time In Full includes practical guidance for tackling the big issues affecting supply chains including: How to understand your extended supply chain with a value stream map The role of forecasting in your supply chain and how to get a meaningful forecast Calculating the right level of inventory for your business Scheduling daily production to meet demand Managing suppliers and your supply chain at home and internationally Selecting and making the best use out of an ERP system Designing an efficient distribution network The book is full of practical case studies and examples as well as references for further study. On Time, In Full is the complete guide to setting up a supply chain that works.
Organizations enjoy two kinds of strategic advantages. One is transitory: being in the right place with the right products at the right time. The other comes from having first class management and instituting processes that mobilize an organization, keeping in ahead of the competition. Which would you like to count on for your organization's success?
This book introduces fundamental, advanced, and future-oriented scientific quality management methods for the engineering and manufacturing industries. It presents new knowledge and experiences in the manufacturing industry with real world case studies. It introduces Quality 4.0 with Industry 4.0, including quality engineering tools for software quality and offers lean quality management methods for lean manufacturing. It also bridges the gap between quality management and quality engineering, and offers a scientific methodology for problem solving and prevention. The methods, techniques, templates, and processes introduced in this book can be utilized in various areas in industry, from product engineering to manufacturing and shop floor management. This book will be of interest to manufacturing industry leaders and managers, who do not require in-depth engineering knowledge. It will also be helpful to engineers in design and suppliers in management and manufacturing, all who have daily concerns with project and quality management. Students in business and engineering programs may also find this book useful as they prepare for careers in the engineering and manufacturing industries. Presents new knowledge and experiences in the manufacturing industry with real world case studies Introduces quality engineering methods for software development Introduces Quality 4.0 with Industry 4.0 Offers lean quality management methods for lean manufacturing Bridges the gap between quality management methods and quality engineering Provides scientific methodology for product planning, problem solving and prevention management Includes forms, templates, and tools that can be used conveniently in the field
This book shows how to consistently obtain annual and multiannual manufacturing target profit regardless of the evolution of sales volumes, increasing or decreasing, using the Manufacturing Cost Policy Deployment (MCPD) system. Managers and practitioners within the manufacturing companies will discover a practical approach within the MCPD system that will help them develop and support their long-term, medium-term, and short-term profitability and productivity strategy. The book presents both the basic concepts of MCPD and the key elements of transforming manufacturing companies through MCPD system, as well as supporting the consistent growth of external and internal profit by directing all systematic and systemic improvements based on meeting the annual and multiannual Manufacturing Cost Improvement (MCI) targets and means for each Product-Family Cost (PFC). This book is unique because it presents two types of systematic and systemic improvement projects for MCI that have been applied over the years in various multinational manufacturing companies operating in highly competitive markets, in order to address the consistent reduction of unit manufacturing costs by improving the Cost of Losses and Waste (CLW). Readers will discover the practical approach of MCI based on a structured approach to MCPD system beyond the traditional approach to manufacturing improvements based mainly on improved time and quality. Therefore, from the perspective of the MCPD system, the multiannual manufacturing target profits are met while the annual and multiannual manufacturing target costs are a predetermined stake and not a result of the improvements already made.
Das Kleben gilt in der industriellen Fertigung als unverzichtbare Alternative zum Schweissen und Loten. Den aktuellen Stand der Klebe-Technologie stellt das bewahrte, in der 6. Auflage erscheinende Fachbuch dar. Die Neuauflage dokumentiert den neuesten Wissensstand auf der Grundlage von zwolf nationalen und internationalen Fachzeitschriften sowie 140 nationalen und europaischen Patentschriften. Mit dem Buch sollen Klebstoffanwender und -hersteller in ihrem Bestreben unterstutzt werden, die Potenziale des Fertigungssystems Kleben nutzbar zu machen."
While there are many books written on the basics of the "supply" side of the supply chain (i.e. strategic sourcing, sourcing/procurement, and purchasing), there hasn't been much written on those areas from a Lean perspective. Considering that supply chain costs, primarily procurement and transportation, can range from 50 to 70% of sales, it's surprising that this area has not been fully explored. As a result, some companies tend to place too much emphasis on the traditional focus of reducing material costs instead of process improvement. Lean Demand-Driven Procurement: How to Apply Lean Thinking to Your Supply Management Process details the basic supply management concepts and processes (i.e. sourcing, procurement, and purchasing) in an easy-to-understand format in combination with various process improvement tools, methodologies, best practices, examples, and cases written from a Lean perspective. It focuses and pinpoints ways to identify waste on the supply side through improved processes and, in some cases, technology. Applying Lean principles to procurement and purchasing processes identies non-traditional sources of waste, and in some cases, creates a paradigm shift that results in additional benets to the entire supply chain.
This book provides advanced techniques for precision compensation and fault diagnosis of precision motion systems and rotating machinery. Techniques and applications through experiments and case studies for intelligent precision compensation and fault diagnosis are offered along with the introduction of machine learning and deep learning methods. Machine Learning-Based Fault Diagnosis for Industrial Engineering Systems discusses how to formulate and solve precision compensation and fault diagnosis problems. The book includes experimental results on hardware equipment used as practical examples throughout the book. Machine learning and deep learning methods used in intelligent precision compensation and intelligent fault diagnosis are introduced. Applications to deal with relevant problems concerning CNC machining and rotating machinery in industrial engineering systems are provided in detail along with applications used in precision motion systems. Methods, applications, and concepts offered in this book can help all professional engineers and students across many areas of engineering and operations management that are involved in any part of Industry 4.0 transformation.
Project Management: Theory and Practice, Third Edition gives students a broad and real flavor of project management. Bringing project management to life, it avoids being too sterilely academic and too narrowly focused on a particular industry view. It takes a model-based approach towards project management commonly used in all industries. The textbook aligns with the latest version of the Project Management Institute's Project Management Body of Knowledge (PMBOK (R)) Guide, which is considered to be the de facto standard for project management. However, it avoids that standard's verbiage and presents students with readable and understandable explanations. Core chapters align with the Project Management Institute's model as well as explain how this model fits real-world projects. The textbook can be used as companion to the standard technical model and help those studying for various project management certifications. The textbook takes an in-depth look at the following areas important to the standard model: Work Breakdown Structures (WBS) Earned Value Management (EVM) Enterprise project management Portfolio management (PPM) Professional responsibility and ethics Agile life cycle The text begins with a background section (Chapters 1-9) containing material outside of the standard model structure but necessary to prepare students for the 10 standard model knowledge areas covered in the chapters that follow. The text is rounded out by eight concluding chapters that explain advanced planning approaches models and projects' external environments. Recognizing that project management is an evolving field, the textbook includes section written by industry experts who share their insight and expertise on cutting-edge topics. It prepares students for upcoming trends and changes in project management while providing an overview of the project management environment today. In addition to guiding students through current models and standards, Project Management: Theory and Practice, Third Edition prepares students for the future by stimulating their thinking beyond the accepted pragmatic view.
With 30 years of driving Lean transformations under his belt-both in-house at Danaher and as the founder of Lean Horizons-Mark C. DeLuzio has a vantage point across a variety of industries. He often hears the challenges Lean leaders face now that they've been implementing Lean for a decade or more. They are concerned that they aren't getting the results they used to, and they don't know why. Most leaders believe their problems are unique to their company, but Mark sees more commonalities than differences. Flatlined: Why Lean Transformations Fail and What to Do About It draws on the author's experience as the original pioneer of the most successful Lean business system next to Toyota, as well as his progress over the past 18 years in helping companies replicate what Danaher achieved. Mark DeLuzio knows you need an actionable approach to make rapid shifts, not theory. With this book, Mark DeLuzio gives you: * the reasons why companies are now flatlining with Lean; * five steps to solving this problem, no matter what your industry or corporate culture; * real talk on why your organization is probably mediocre (even if it's making a lot of money) and how to disrupt it to make it genuinely world class; * the questions you should always be asking at every stage and level of your Lean initiative.
Lean - Let's Get It Right!: How to Build a Culture of Continuous Improvement (978-0-367-42991-1, 340939) Shelving Guide: Business & Management / Lean Management This book addresses the root causes of why a majority of Lean transformations have not met expectations. More importantly, it provides the information needed to turn around the failure mechanisms and transform them into critical success factors. Lean - Let's Get It Right! delves into the psychology of change and motivation and clarifies the roles and responsibility changes which are required for alignment with Lean principles. While the author includes a review of Lean principles, the majority of the book either provides more depth of understanding of the principles or highlights how misalignment can thwart Lean transformation efforts. What this provides is not only clarity, but it establishes a solid reference point or framework to guide the Lean strategy. The reader will begin to see how the principles are not simply a random set of characteristics or features of Lean, but are actually a set of fundamental beliefs on which all else is based. Though repeated throughout the book that an organization must develop the specifics of their own Lean roadmap, this book concludes with guidance on making it happen. This book, with its primary focus on people, leadership, and principles, and less so on the details of tools and techniques, can be thought of as providing the few critical missing puzzle pieces to enable an effective Lean transformation.
Part of the Toyota Production System, Kamishibai boards are simple and flexible visual controls for performing audits within a manufacturing process. When used properly, they are powerful tools for performing, managing, and auditing tasks of specific duties. Kamishibai Boards: A Lean Visual Management System That Supports Layered Audits explains how to use this visual management system to identify normal conditions versus abnormal conditions in your organization. Filled with easy-to-follow instructions that require minimal training, it outlines a layered audit system for sustaining continuous improvement that can be applied to any organization in any industry. The book includes downloadable resources with master forms you can use to create your own daily, weekly, or monthly Kamishibai cards for any subject. The downloadable resources also include electronic copies of all examples in the book. Helping you focus on resolving abnormal situations, the book supplies the understanding required to make problems, abnormalities, and variations from the standard visible so corrective actions can be made right away-so you can spend more of your valuable time on achieving sustainable improvement.
Good engineers never stop looking for opportunities to improve the performance of their production systems. Performance enhancement methods are always carefully examined, and production data is analyzed in order to identify determining factors affecting performance. The two main activities of the production engineer in the petroleum and related industries are reservoir stimulation and artificial lift. The classic solution to maximizing a well's productivity is to stimulate it. The basis for selecting stimulation candidates should be a review of the well's actual and theoretical IPR. Low permeability wells often need fracturing on initial completion. In low permeability zones, additional post stimulation production can be significant to the economics, however, the production engineer needs to make management aware of the true long term potential or else overly optimistic projections can easily be made. The main purpose of stimulation is to enhance the property value by the faster delivery of the petroleum fluid and/or to increase ultimate economic recovery. The aim of reservoir stimulation is to bypass near-wellbore damage and return a well to its "natural" productivity / injectivity, to extend a conductive path deep into a formation and thus increase productivity beyond the natural level and to produce hydrocarbon from tight formation. The importance of reservoir stimulation is increasing due to following reasons: * Hydrocarbon fields in their mid-life * Production in these fields are in declining trend * The thrust area: Enhancement of production Hence, to improve productivity of the well matrix stimulation and hydraulic fracturing are intended to remedy, or even improve, the natural connection of the wellbore with the reservoir, which could delay the need for artificial lift. This book presents procedures taken in the Oil & Gas Industry for identifying well problems, and it suggests means of solving problems with the help of the Coil Tube unit which is used for improving well productivity and techniques like Acidizing and Hydraulic Fracturing.
A valuable tool for establishing and maintaining system reliability, overall equipment effectiveness (OEE) has proven to be very effective in reducing unscheduled downtime for companies around the world. So much so that OEE is quickly becoming a requirement for improving quality and substantiating capacity in leading organizations, as well as a required area of study for the ISO/TS 16949. Breaking down the methodology from a historical perspective, The OEE Primer: Understanding Overall Equipment Effectiveness, Reliability, and Maintainability explores the overall effectiveness of machines and unveils novel methods that focus on design improvement-including hazard analysis, rate of change of failure (ROCOF) analysis, failure rate finite element analysis (FEA), and theory of inventive problem solving (TRIZ). It covers loss of effectiveness, new machinery, electrical maintenance issues, Weibull distribution, measurement techniques, and mechanical and electrical reliability. The book also: Discusses Reliability and Maintainability (R&M), not as tools to be used in specific tasks, rather as a discipline Covers the application of OEE as an overall improvement tool Assesses existing and new equipment from classical, reliability, and maintainability perspectives Includes downloadable resources with more than 100 pages of appendices and additional resources featuring statistical tables, outlines, case studies, guidelines, and standards Introducing the classical approach to improvement, this book provides an understanding of exactly what OEE is and how it can be best applied to address capacity issues. Highlighting mechanical and electrical opportunities throughout, the text includes many tables, forms, and examples that clearly illustrate and enhance the material presented.
The Lean Anthology: A Practical Primer in Continual Improvement presents operations management case studies that illustrate a Lean process improvement journey. Ideal for non-engineers, adult learners, and corporate or business education settings, this book can help you and your organization understand and apply Lean practices as part of a plan for saving money, generating revenues, or freeing up resources particularly in settings not traditionally associated with Lean.The stories are easy to understand, simple accounts of everyday people negotiating life. The characters observe and integrate the principles of Lean into their personal and professional lives. Each Lean case study will help you understand and apply a different approach to the "relentless pursuit of the strategic elimination of waste."The stories are organized into a framework for implementing a Lean transformation called The Five Cs: Customer, Capability, Control, Coordination, and Context/Culture. These are the five stages of strategic operations design and improvement. The Five Cs framework is a new approach to understanding a Lean journey that you can apply in many settings. The Five Cs framework can help you become more effective in both your personal and professional lives.The book includes explanations with each case study, as well as brain teasers suitable for team discussion. These tools supply readers even those without an operations management background with an intuitive understanding of how to create value by eliminating waste. |
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