Lean for the process industries

Author: Peter L. King
Publisher: Productivity Press
ISBN:
Format: PDF, Mobi
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Most available material on Lean describes applications only in the assembly industries: automotive, machinery, computers, appliances, and the like. This book describes the application of Lean Manufacturing concepts to the process industries: sheet goods, fibers, architectural and automotive paints, food, beverage, plastics, synthetic rubber, batch chemicals, fertilizers, and pharmaceuticals. The book begins by describing characteristics which differentiate the process industries from assembly manufacturing, particularly those which influence how Lean must be applied for greatest benefit. Factors affecting dynamic flow behavior through each of the two are described, as well as a hypothetical process industry example, which is used throughout the book to illustrate application of specific lean tools.

Value Stream Mapping for the Process Industries

Author: Peter L. King
Publisher: CRC Press
ISBN: 1482247690
Format: PDF, ePub
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Providing a framework that highlights waste and its negative effects on process performance, value stream maps (VSMs) are essential components for successful Lean initiatives. While the conventional VSM format has the basic structure to effectively describe process operations, it must be adapted and expanded to serve its purpose in the process industry. This book describes in detail how to create a complete VSM for a process industry manufacturing operation. Detailing the unique features of process operations and why they require additions and adjustments to traditional VSMs, the book walks readers through the steps in analyzing the map. It explains how to scope improvement projects, prioritize them, and then use future state VSMs to illustrate and motivate systemic improvement. In doing so, it supplies readers with a roadmap for a complete Lean transformation. Describes how to analyze the map for waste and flow issues so that they can be reduced and even eliminated Provides examples of the calculations needed for the flow parameters in data boxes Explains how the VSM concept can be applied to the entire supply chain Includes strategies for engaging your entire workforce in map creation The book introduces a target manufacturing process and uses it to describe how to create a complete VSM. The target process is complex enough to illustrate the issues often encountered in mapping a process industry operation, but straightforward enough to explain all of the mapping considerations and decisions. The book includes real examples of how VSMs brought much greater clarity to the real issues the processes faced and cases where the insight enabled management to avoid costly, inappropriate investments.

The Product Wheel Handbook

Author: Peter L. King
Publisher: CRC Press
ISBN: 1466554193
Format: PDF, ePub, Docs
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The Product Wheel (PW) design process has practical methods for finding the optimum sequence, minimizing changeover costs, and freeing up useful capacity. So much so, that the DuPontTM Company and Exxon Mobil are just a few companies that have used the product wheel concept to achieve and sustain a competitive advantage. Breaking down a fairly complex design process into manageable steps, The Product Wheel Handbook: Creating Balanced Flow in High-Mix Process Operations walks readers through the process for designing and implementing the PW technique. It includes a case study taken from actual practice that illustrates the design process and its benefits. Describing how to apply the product wheel technique to any manufacturing operation, the book: Details the steps required to implement product wheels Explains why certain traditional manufacturing metrics should be reevaluated so they don’t inhibit product wheel performance Defines the cultural foundation necessary for smooth product wheel design and implementation Includes a real-world case study and several examples of product wheels being used by successful manufacturing companies—including BG Products, Inc., the DuPontTM Company, the Dow Chemical Company, and Appleton Many of the steps in wheel design described in this book are not new. What’s new is their application to production planning and scheduling problems, and more importantly, a clear roadmap explaining how and when they should be used in product wheel design. Supplying you with the tools to reduce the chaos often found in production scheduling, the book outlines a disciplined structure that will allow you to spend less of your time resolving schedule problems. Most importantly, it provides your organization with a stable platform to deal with abnormal events in a less stressful and more logical manner.

Ganzheitliche Produktionssysteme

Author: Uwe Dombrowski
Publisher: Springer-Verlag
ISBN: 3662461641
Format: PDF, ePub
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Kaum ein Unternehmen kann es sich heutzutage leisten, die Potenziale Ganzheitlicher Produktionssysteme (GPS) ungenutzt zu lassen. Mit GPS werden herausragende Erfolge bei der Verbesserung der Qualität, der Reduzierung von Durchlaufzeiten und der Steigerung der Produktivität sowie zahlreicher weiterer Zielgrößen ermöglicht. GPS haben ihren Ursprung zwar in der Automobilindustrie, inzwischen haben sie sich aufgrund des großen Erfolgs jedoch in verschiedensten Branchen als Industriestandard etabliert. Dieses Buch bietet eine umfassende Darstellung der Thematik und stellt hierfür die relevanten Inhalte zu Grundlagen, Einführung und Weiterentwicklung vor. Die grundlegende Struktur Ganzheitlicher Produktionssysteme wird systematisch anhand der Gestaltungsprinzipien der VDI 2870 beschrieben und mit zahlreichen Praxisbeispielen erläutert. Auf diese Weise erhält der Leser viele interessante Einblicke und Erkenntnisse für Praxis, Forschung und Lehre.

LEAN Supply Chain Planning

Author: Josef Packowski
Publisher: CRC Press
ISBN: 1482205343
Format: PDF, Docs
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Delivering excellent service to all customers is the key imperative for many sustainable businesses. So why do so many supply chains struggle to fulfill customer requirements at competitive costs? The answer is simple: traditional supply chain planning, which was tailored to a predominantly stable and predictable business environment, cannot handle the new challenges in the world of variability, uncertainty, complexity, and ambiguity—the VUCA world. Companies can either accept the drawbacks that often result in high inventories, poor asset utilization, and unsatisfactory customer service or, they can change their view of the fundamental approach to supply chain management. LEAN Supply Chain Planning: The New Supply Chain Management Paradigm for Process Industries to Master Today’s VUCA World introduces a new paradigm and a new approach to managing variability, uncertainty, and complexity in today’s planning processes and systems. Introducing a cutting-edge supply chain management concept that addresses current problems in the process industry's supply chains, the book presents powerful methods developed by leading research institutes, process industry champions, and supply chain experts. It explains how readers can change their approach to the fundamental planning paradigms in a manner that will help their organizations achieve higher levels of responsiveness, improved levels of customer service, and substantial increases in cost-efficiencies. This holistic practitioner’s guide describes how to establish the right accountabilities for performance management and also provides a set of meaningful metrics to help measure your progress. Supplying detailed guidelines for transforming your supply chain, it includes first-hand reports of leading organizations that have already adopted some of the facets of this paradigm and used the relevant instruments to achieve unprecedented improvements to customer service, supply chain agility, and overall equipment effectiveness.

Lean Pedagogy

Author: Benjamin Chibaira
Publisher: BookBaby
ISBN: 148355970X
Format: PDF, Mobi
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In this book, the author challenges the status quo in schools with an emphasis on students’ results, and the associated costs, and curriculum lead times for achieving these results. Policy and curriculum changes, as well as funding initiatives, have been the most common interventions for the prominent systemic issues faced by schools. However, these have proven neither effective nor sustainable in the long term . In addition, education reforms have barely considered the very processes that influence the classroom outcomes. In this book, the author proposes a process focused pedagogy based on tried and tested Lean principles and tools in order to achieve the elusive classrooms outcomes. Lean is a process-focused methodology, which considers any expenditure of resources for any goal other than the creation of customer value as wasteful, and thus targets it for elimination. "Value" is described as any action for which a customer would be willing to pay for. Lean Thinking has roots in the automotive industry although it is now widely used in both the private and public sectors. In spite of Lean’s successes in industry, it has barely made inroads into education and thus this inspired a case study to test it application in a classroom. Through the application of such, improvements were achieved in both the student’s results and the time it took to complete the curriculum. The role of this book is to show why Lean Thinking in schools is an important alternative in the pursuit for improving results, costs, and curriculum lead times. This book will appeal to different groups of readers including educators, students, school governing bodies, parent’s school improvement specialists, Lean practitioners, general readers, as well as schools which are ready to pursue excellence through continuous improvement tools. A simplified version of the checklist used to assess a school’s status in its readiness for a Lean intervention is in provided. A typical timeline for planning purposes for schools wishing to pursue this Lean journey is also provided . Further, more detailed implementation manuals are available through Lean Fundo

Der Toyota Weg

Author: Liker Jeffrey K.
Publisher: FinanzBuch Verlag
ISBN: 3862484440
Format: PDF, ePub, Docs
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Mit seiner Unternehmensführung ist Toyota seit langem Vorbild für Firmen aus den unterschiedlichsten Branchen. Fast alle Automobilhersteller versuchten mehr oder weniger erfolgreich das legendäre Toyota-Produktionssystem (TPS) zu kopieren, das zum Ziel hat, die Kundenzufriedenheit in den drei Bereichen Qualität, Lieferzeit und Kosten zu erhöhen. Aufgrund des verschärften Wettbewerbs in der Automobilbranche drängt sich jetzt die Frage nach den Faktoren des Erfolgs immer mehr in den Mittelpunkt. Jeffrey K. Liker befasst sich in seinem Buch „Der Toyota Weg“ ausführlich mit dem warum und wieso. Aus zahlreichen Interviews und eigenen Anschauungen filtert der Autor die 14 Managementprinzipien heraus, die den Kern des Toyota-Erfolgs ausmachen. Diese Prinzipien untermauert er eindrucksvoll mit einer Fülle von Details, Anekdoten und Interview-Auszügen. Leicht verständlich erklärt er dem Leser die Managementsysteme, die Denkweise und die Philosophie, auf denen der Erfolg von Toyota basiert. So vermittelt er wertvolle Erkenntnisse, die sich auf jeden beliebigen Geschäftszweig bzw. jede Geschäftssituation übertragen lassen.

A Systems Approach to Managing the Complexities of Process Industries

Author: Fabienne Salimi
Publisher: Elsevier
ISBN: 0128042184
Format: PDF, ePub
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A Systems Approach to Managing the Complexities of Process Industries discusses the principles of system engineering, system thinking, complexity thinking and how these apply to the process industry, including benefits and implementation in process safety management systems. The book focuses on the ways system engineering skills, PLM, and IIoT can radically improve effectiveness of implementation of the process safety management system. Covering lifecycle, megaproject system engineering, and project management issues, this book reviews available tools and software and presents the practical web-based approach of Analysis & Dynamic Evaluation of Project Processes (ADEPP) for system engineering of the process manufacturing development and operation phases. Key solutions proposed include adding complexity management steps in the risk assessment framework of ISO 31000 and utilization of Installation Lifecycle Management. This study of this end-to-end process will help users improve operational excellence and navigate the complexities of managing a chemical or processing plant. Presents a review of Operational Excellence and Process Safety Management Methods, along with solutions to complexity assessment and management Provides a comparison of the process manufacturing industry with discrete manufacturing, identifying similarities and areas of customization for process manufacturing Discusses key solutions for managing the complexities of process manufacturing development and operational phases

Liquid Lean

Author: Raymond C. Floyd
Publisher: CRC Press
ISBN: 9781420088632
Format: PDF
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While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author’s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of the problem is resistance to transformational change, a barrier that can only be overcome with effective leadership and results-oriented planning that engages rather than excludes all stakeholders. Winner of a 2012 Shingo Prize! Written by Raymond Floyd, an unparalleled leader of Lean transformations, Liquid Lean: Developing Lean Culture in the Process Industries provides potential process industry change agents with the no-nonsense guide needed to eliminate waste and achieve sustainable optimal efficiency. Presenting lessons in lean as they apply within the liquid industries, the book focuses on developing the four measures of Lean as defined by the Shingo Award: Business Results Consistent Lean Enterprise Culture Continuous Process Improvement Cultural Enablers Illustrated with his own success stories, Floyd describes business results, Lean enterprise thinking, and policy deployment in process industry terms. He offers detailed theory, practice, and examples of continuous process improvement, and describes the leadership and defines the ethics needed to evolve and sustain Lean transformation. Floyd lays out the specific steps needed during the first six months of transformation and the benchmarks to be achieved during the first two years of implementation. All companies can benefit from Lean; this book makes sure that those who want it, know how.