Lean Manufacturing (EPT 484/2)

A practical guide on how to truly implement Lean Manufacturing enterprise wideLean manufacturing is a powerful formula for eliminating waste, controlling quality and inventory, and improving overall performance with the promise of huge early gains. This prescriptive guide offers real-world solutions for implementing lean manufacturing in the enterprise, covering the technical, engineering, and production aspects as well as the business culture concerns.How To Implement Lean Manufacturing specifies the distinct order in which a company should implement lean, and discusses common reasons why certain companies have failed in their implementations. Global case studies help readers easily apply these situations to their own companies.

The delivery of real bottom-line results from manufacturing improvements has proven to be much harder than expected for most companies. TQM, Zero-Defect Manufacturing, and Business Process Re-engineering have dropped off the landscape for taking much too long and failing to deliver the promised results. Lean Six Sigma is now experiencing the same fundamental difficulty. Delineating a quantitative approach, Lean Manufacturing: Business Bottom-Line Basedshows you how to revitalize Lean Six Sigma by aligning it with your business’ bottom line and thus delivering results that your executives, business leaders, and customers expect. Written by an expert who has transformed product design and manufacturing at companies ranging from Maytag and Visteon to General Electric, the book demonstrates that an awareness of manufacturing business metrics is absolutely essential for every lean manufacturing practitioner. The author has seen first-hand the limitation of traditional lean manufacturing driven by business bottom lines. He outlines case studies linking world events and manufacturing efficiency and presents lean manufacturing strategies and techniques designed to accelerate responses to current and future events on the floors of the world’s manufacturing facilities. Typically, advice on lean manufacturing comes in the form of techniques regarding a particular tool or tool-box, yet the factory floor, like everything in the global community, is profoundly driven by business bottom lines. This book presents a systematic approach to improve business bottom lines through identifying and eliminating waste, and adding value and fulfillment by flowing the product at the demand of the customer.

All companies which reach a critical size are faced with outsourcing decisions that can increase the value of their products and services primarily through lower costs, greater reliability and improved efficiency. Successful outsourcing decisions have an important knowledge dimension, where the outsourcing professionals need to be supported by historical and contextual knowledge regarding their own products performance but also the performance of suppliers. Outsourcing in Manufacturing: the Knowledge Dimension explains in detail how a manager can acquire, create, transfer and use knowledge that optimizes their outsourcing decisions and improves the changes of marketplace success.             Outsourcing in Manufacturing: the Knowledge Dimension gives examples of the key decisions that needs to be taken by managers regarding effective outsourcing. Decisions are divided around the structural and infrastructural aspects of outsourcing and the key knowledge that needs to be managed to support good decisions. The book contains illustrations and examples of key processes throughout and concludes with a section dedicated to case studies. These case studies represent a variety of manufacturing system types and sizes focused on supply chain integration, and which deploy various manufacturing paradigms including craft, mass, lean, adaptive, and sustainable manufacturing.  Outsourcing in Manufacturing: the Knowledge Dimension covers many theoretical and practical examples of critical outsourcing decisions, their knowledge aspects and how knowledge challenges can be dealt with in a systematic way. It provides a key resource for students, lecturers and industry managers looking to solidify their understanding and application of outsourcing decision making strategies..

There are some very good books available that explain the Lean Manufacturing theory and touch on implementing its techniques. However, you cannot learn "how to be" lean from merely reading the theory. And to be successful in the real-work environment you need a clear comprehension of how lean techniques work, rather than just a remote understanding of what they are. You need to know what does and does not work in different situations. And you need the benefit of practical experience in their implementation. Lean Manufacturing: Tools, Techniques, and How to Use Them gives you the benefit of author and practitioner William Feld's 15 years of hands-on experience - and the lessons he's learned. Feld provides insight into the appropriate use of assessment, analysis, design, and, most importantly, deployment of a successful lean manufacturing program. Packed with practical advice and tips but not bogged down in theory, this book covers how, why, when, and what to do while implementing lean manufacturing. It equips you with the tools and techniques you need along with an understanding of how and why they work. Feld explores why an integrated approach is so much more beneficial in securing sustained improvement. He focuses on the interdependency of the Five Primary Elements: organization, metrics, logistics, manufacturing flow, and process control. He describes a proven, applied approach to creating a lean program using these elements. To keep up globally, and even locally, your manufacturing operation must be responsive, flexible, predictable, and consistent. You must continually improve manufacturing operations and cultivate a self directed work force driven by output based, customer performance criteria. By applying what you learn from Lean Manufacturing: Tools, Techniques, and How to Use Them you can build a workforce - and an organization - with the capacity to satisfy world class expectations now and into the future.

The first book to address today's range of manufacturing quality improvement tools, with an eye toward enterprise alignment, cost control and productivity improvement

This volume provides detailed coverage of the automotive manufacturing processes and discusses all the scientific (theory) and procedural aspects of each process.