Lean Manufacturing for the Small Shop
   Gary B. Conner

Companies of all sizes are in a desperate race to remain competitive and profitable. Written with Lean implementers in mind, this text is designed to help companies and change agents apply the tools of Lean quickly. Much has been written about larger companies and Original Equipment Manufacturers (OEMs) that implemented the Lean techniques perfected at Toyota within the last few decades. However, less attention has been offered addressing the special needs of smaller companies, job shops, and even "Mom and Pop" shops. While acknowledging some similarities, this book points out critical and distinct differences between OEM organizations and make-to-order environments. Hybrid methods of implementation for the Lean techniques are necessary and this book helps provide such an approach. The principles of the Toyota Production system are sound and proven. They are effective in any industry and within any company. The challenge is to apply the right tool, at the right place, at the right time, while maintaining the flexibility and nimble nature required of smaller shops. The steps outlined in this text will assist your organization reach the goals you have set for yourselves in terms of Delivery performance, Quality, and Cost. Book includes a CD-ROM that contains useful training tools, examples, and samples. Instructors can adapt visuals for classes or training.

275 pp, 76 Illustrations, 40 Tables, Equations 2001   Price US$ 65.00 (Approx RS 3250.00)

 
CONTENTS
  1.  It's About Time - Trading Time for Dollars - Make versus Buy - Evolution of a Company - The Beginning
  2.  The Lean Enterprise Vehicle - Wheels,Spokes,and the Radar Chart - Sales,Production,and Inventory Management - Total Organizational Buy-in - Total    Quality Management - Lean Manufacturing Techniques
  3. Introduction to a Small Manufacturing Company - Understanding Kaizen - Performance Evaluation - Value Stream Mapping - Product-Quantity-Routing Analysis - Value-added versus Non-value-added Activities
  4. Value Stream Mapping - Value Stream Symbols - Four Steps to Value Stream Mapping - Step 1:Product Development - Step2:Process Design - Step3:Preparation - Step4:Planning
  5. Lead Time and Activity - Dealing with Different Processes - Value-added versus Non-value-added Ratios - Product Demand Patterns
  6. Optimum Lot Size - Determine How Much to Make - Hour-by-Hour- Charts - A New Use for Economic Order Quantity - Re-educating the Customer - Single-minute Exchange of Die
  7. Just-in-Time Techniques - SMED - The Fast Setup Toolbox - Videotaping - Brainstorming - Setup Reduction - Reducing Time - Testing the Solution - Calculating Takt Times - Getting the Process to Flow - Standard Work - Line Balancing - Machine Reliability - Jidoka and Poka-Yoke - Pull Systems - Facilities Planning - Back to the Jobbe Shoppe - Material Handling Reduction - Summary
  8. Managing Change - Needs of the People - Vision - Skills - Incentives - Resources - Planning
  9. Quality System Management  : Tools for the Team - Total Quality Management - Linearity Charts (Productivity and Waste) - Ishikawa Diagrams (Cause-and-effect) - Quality Maps - Process Flow Diagram - Deployment Flow Diagram - Paroto Analysis - Alternative Selection Worksheet - Process Control - Pre-control - Buddy Check - Summary
  10. People Make a Difference - Undoing Negative Actions - Helping People Do Great Work - Choice:A Tool to Create Business People - The Entrepreneurial Spirit - What Makes a Businessperson? - Wage Structures for the New Century - Incentive Programs - Summary
  11. Training - Training Considerations - Promoting from Within the Company - High-involvement Training - Training the Trainers - Trainer Qualifications - Adults versus Child Learners - Communication Styles - Teach Back - summary
  12. Team Structure for the 21st Century - Tools for Improving the Team - Peer-to-Peer Evaluations - Determining a Leader - Summary
  13. The Road to Lean - Adopting the Lean Approach - Vision Statement - Broad Objectives - First Year Objectives - Program Organization - Celebrate the Journey
  14. Chooses Your Battles Carefully - Successful Tactics - A Lesson from the Civil War - Building a Time-phased Model - Strategic Planning - The Right Tools for the Job - Every Cause Needs a Leader - The Little Brother Effect - Summary