How To Implement Lean Manufacturing

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McGraw Hill Professional, Jul 6, 2009 - Technology & Engineering - 304 pages

A Practical, Hands-on Guide to Lean Manufacturing

This real-world resource offers proven solutions for implementing lean manufacturing in an enterprise environment, covering the engineering and production aspects as well as the business culture concerns. Filled with detailed examples, the book focuses on the rapid application of lean principles so that large, early financial gains can be made.

How to Implement Lean Manufacturing explains Toyota Production System (TPS) practices and specifies the distinct order in which lean techniques should be applied to achieve maximum gains. Global case studies illustrate successes and pitfalls of lean manufacturing initiatives. Discover how to:

  • Rigorously test and retest the state of your "leanness" with unique evaluators
  • Develop and deploy plant-wide strategies and goals
  • Improve speed and quality and dramatically reduce costs
  • Reduce variation in the manufacturing system in order to reduce inventory
  • Reduce lead times to enable improved responsiveness and flexibility
  • Synchronize production and supply to the customer
  • Create flow and establish pull-demand systems
  • Perform system-wide and specific value-stream evaluations
  • Generate a comprehensive list of highly focused Kaizen activities
  • Sustain process gains
  • Manage constraints and reduce bottlenecks
  • Implement cellular manufacturing

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Contents

1 What Is the Perspective of This Book?
1
2 Lean Manufacturing and the Toyota Production System
9
3 Inventory and Variation
41
4 Lean Manufacturing Simplified
59
5 The Significance of Lead Time
73
6 How to Do LeanCultural Change Fundamentals
87
7 How to Do LeanThe Four Strategies to Becoming Lean
111
8 How to Implement LeanThe Prescription for the Lean Project
135
13 Cellular Manufacturing
195
14 The Story of the Alpha Line
211
A Tale of Reduced Lead Times and Lots of Early Gains
221
16 Using the PrescriptionThree Case Studies
235
17 The Precursors to Lean Not Handled Well
273
18 An Experiment in Variation Dependent Events and Inventory
285
19 Assessment Tools
291
20 A House of Lean
299

9 Planning and Goals
153
10 Sustaining the Gains
163
11 Cultures
179
12 Constraint Management
189
Glossary
301
Bibliography
309
Index
311
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About the author (2009)

Lonnie Wilson founded Quality Consultants which serves small and Fortune 500 firms. He has 20 years of experience in manufacturing management with an international oil company.

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