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With examples drawn from aerospace, electronics, household appliance, personal products, and automotive industries, Lean Assembly covers the engineering of assembly operations through: Characterizing the demand in terms of volume by product and product family, component consumption, seasonal variability and life cycle. Matching the physical structure of the shop floor to the demand with the goal of approaching takt-driven production as closely as possible. Working out the details of assembly tasks station by station, including station sizing, tooling, fixturing, operator instructions, part presentation, conveyance between stations, and the geometry of assembly lines as a whole. Incorporating mistake-proofing, successive inspection, and test operations for quality assurance. Lean Assembly differs from most other books on lean manufacturing in that it focuses on technical content as a driver for implementation methods. The emphasis is on exactly what should be done. This book should be the "dog-eared" and "penciled-in" resource on every assembly engineer's desk.
With examples drawn from aerospace, electronics, household appliance, personal products, and automotive industries, Lean Assembly covers the engineering of assembly operations through: Characterizing the demand in terms of volume by product and product family, component consumption, seasonal variability and life cycle. Matching the physical structure of the shop floor to the demand with the goal of approaching takt-driven production as closely as possible. Working out the details of assembly tasks station by station, including station sizing, tooling, fixturing, operator instructions, part presentation, conveyance between stations, and the geometry of assembly lines as a whole. Incorporating mistake-proofing, successive inspection, and test operations for quality assurance. Lean Assembly differs from most other books on lean manufacturing in that it focuses on technical content as a driver for implementation methods. The emphasis is on exactly what should be done. This book should be the "dog-eared" and "penciled-in" resource on every assembly engineer's desk.
It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demon
It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation. Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them. Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.
In the 1950’s, the design and implementation of the Toyota Production System (TPS) within Toyota had begun. In the 1960’s, Group Technology (GT) and Cellular Manufacturing (CM) were used by Serck Audco Valves, a high-mix low-volume (HMLV) manufacturer in the United Kingdom, to guide enterprise-wide transformation. In 1996, the publication of the book Lean Thinking introduced the entire world to Lean. Job Shop Lean integrates Lean with GT and CM by using the five Principles of Lean to guide its implementation: (1) identify value, (2) map the value stream, (3) create flow, (4) establish pull, and (5) seek perfection. Unfortunately, the tools typically used to implement the Principles of Lean are incapable of solving the three Industrial Engineering problems that HMLV manufacturers face when implementing Lean: (1) finding the product families in a product mix with hundreds of different products, (2) designing a flexible factory layout that "fits" hundreds of different product routings, and (3) scheduling a multi-product multi-machine production system subject to finite capacity constraints. Based on the Author’s 20+ years of learning, teaching, researching, and implementing Job Shop Lean since 1999, this book Describes the concepts, tools, software, implementation methodology, and barriers to successful implementation of Lean in HMLV production systems Utilizes Production Flow Analysis instead of Value Stream Mapping to eliminate waste in different levels of any HMLV manufacturing enterprise Solves the three Industrial Engineering problems that were mentioned earlier using software like PFAST (Production Flow Analysis and Simplification Toolkit), Sgetti and Schedlyzer Explains how the one-at-a-time implementation of manufacturing cells constitutes a long-term strategy for Continuous Improvement Explains how product families and manufacturing cells are the basis for implementing flexible automation, machine monitoring, virtual cells, Manufacturing Execution Systems, and other elements of Industry 4.0 Teaches a new method, Value Network Mapping, to visualize large multi-product multi-machine production systems whose Value Streams share many processes Includes real success stories of Job Shop Lean implementation in a variety of production systems such as a forge shop, a machine shop, a fabrication facility and a shipping department Encourages any HMLV manufacturer planning to implement Job Shop Lean to leverage the co-curricular and extracurricular programs of an Industrial Engineering department
The Basics of Self-Balancing Processes by Gordon Ghirann Pdf
Self-Balancing is not just a tweak or change to assembly line balancing, but a completely transformed method for achieving continuous flow. Among the reasons you should try Self-Balancing is that you can expect a productivity improvement of at least 30 percent with improvements of 50-60 percent quite common. Using a well-tested method for successful improvements initiated by the author, The Basics of Self-Balancing Processes: True Lean Continuous Flow is the first book to explain how to achieve continuous flow in both simple and complex manufacturing environments. It describes how to recognize and resolve weak links to ensure continuous flow in your manufacturing operations. The book offers rules, tools, and guidelines to help you not only solve problems at the root, but even eliminate them before they start. It reviews the shortcomings of traditional assembly line balancing and walks readers through the new paradigm of Self-Balancing. The text includes a comprehensive overview that demonstrates the power, flexibility, and breakthroughs possible with this method. Offering solutions to the shortcomings associated with standard line balancing including inventory buffers, variation, and operator pace it provides you with the tools and understanding required to deal with batch and off-line processes, debug your line, arrange your parts and tools, and design your own Self-Balanced cells. Watch Gordon Ghirann discuss how his book can increase the productivity of your business. http://www.youtube.com/watch?v=yte0622XbcI&feature=youtu.be
Flow Manufacturing -- What Went Right, What Went Wrong by Richard J. Schonberger Pdf
This book tells 101 stories of company efforts to implement the many aspects of flow manufacturing -- including such topics as just-in-time production, total quality control, reorganization of factories into product-focused or customer-focused cells, plants-in-a-plant, material flows by the simplicity of visual kanban, supplier partnerships, quick setup of equipment, cross-training and job rotation of the work force, and many more. The 101 mini-case studies – dubbed "caselets" -- include 26 non-U.S. companies from 12 countries and cover a wide swath of industrial sectors, and include many well-known corporations such as Apple, Campbell Soup, Honeywell, and Boeing. From the 1980s to the present, the author has been taking the message of process improvement and customer-focused excellence far and wide. Most of these travels, usually in connection with delivering a seminar, include brief factory tours in which he compiled detailed notes and then organized them as brief reports — his unvarnished analysis or take on what they do well and what needs improvement. In the main the reports were then sent back to the hosts of the plant tour. These factory tours and these follow-up reports form the basis of the large majority of this book’s caselets. Many of the caselets bring to life process-improvement methodologies in detail. With lots of caselets to draw from, the readers will find vivid examples of similar companies and processes within their respective industries. For example, the caselets often include applications of advanced concepts in cost management, employee training, performance management, supply chains, and logistics as well as applications of plant layout, quick setup, material handling, quality assurance, scheduling, ergonomics, and flow analysis.
Author : James P. Womack,Daniel T. Jones Publisher : Simon and Schuster Page : 400 pages File Size : 48,5 Mb Release : 2013-09-26 Category : Business & Economics ISBN : 9781471111006
Lean Thinking by James P. Womack,Daniel T. Jones Pdf
Lean Thinking was launched in the fall of 1996, just in time for the recession of 1997. It told the story of how American, European, and Japanese firms applied a simple set of principles called 'lean thinking' to survive the recession of 1991 and grow steadily in sales and profits through 1996. Even though the recession of 1997 never happened, companies were starving for information on how to make themselves leaner and more efficient. Now we are dealing with the recession of 2001 and the financial meltdown of 2002. So what happened to the exemplar firms profiled in Lean Thinking? In the new fully revised edition of this bestselling book those pioneering lean thinkers are brought up to date. Authors James Womack and Daniel Jones offer new guidelines for lean thinking firms and bring their groundbreaking practices to a brand new generation of companies that are looking to stay one step ahead of the competition.
Taking Improvement from the Assembly Line to Healthcare by Ronald G. Bercaw Pdf
According to a report by the Institute of Medicine, up to 98,000 deaths per year occur in U.S. hospitals as a result of adverse events. In other words, errors in hospitals cause more annual deaths than car accidents, breast cancer, or AIDS. With the healthcare system in such critical condition, Lean is the best possible treatment. Winner of a 2013 Shingo Research and Professional Publication Award! Taking Improvement from the Assembly Line to Healthcare: The Application of Lean within the Healthcare Industry supplies step-by-step guidance on how to implement Lean methods to achieve world-class improvement within the healthcare industry. Specific examples of this approach are provided in emergency medicine, diagnostic imaging, orthopedic clinics, general internal medicine, administration, and community care. Highlighting quality, safety, and financial evidence as to why immediate change is both possible and essential, the book provides a firm foundation in Lean improvement and the tools used to deliver sustainable solutions. It presents client interviews and case studies from the U.S. and Canada to provide readers with the real-world understanding needed to embark and sustain a successful improvement journey. With two decades of experience in industrial operations management, Ronald Bercaw details a proven approach for discovering waste and delivering improvement in healthcare organizations. He presents powerful insights gained through successful Lean implementations in private industry, U.S. and Canadian healthcare systems, U.S. Pentagon business systems, U.S. Surgeon General assignments, and U.S. Navy, Army, and Air Force maintenance applications. Providing a comprehensive view of improvement within and outside the walls of the hospital and clinic, the book reveals valuable lessons learned and mitigation strategies to increase your chances of success. It identifies and addresses the leadership challenges that are likely to emerge and includes a detailed roadmap to provide you with the tools needed to achieve sustainable improvements in quality, patient safety, productivity, and staff development and engagement. Watch Ronald Bercaw discuss how to apply the Toyota Production System to the healthcare industry. Part I: http://www.youtube.com/watch?v=XTnKWHZ82vM&feature=youtu.be Part II: http://www.youtube.com/watch?v=tBsoRcKDOaM&feature=youtu.be
Renewable and Sustainable Energy by Wei Guo Pan,Jian Xing Ren,Yong Guang Li Pdf
The extensively peer-reviewed contents of this book cover the development and use of solar energy, nuclear energy engineering, development and use of wind energy, development and use of biomass energy, storage technology, energy-saving technology, hydrogen and fuel-cells, energy materials, energy chemical engineering, energy security and clean use, new energy vehicles, electric vehicles, energy-efficient lighting products and technologies, green building materials and energy-saving buildings. This makes the work a veritable handbook on these topics.
Lean for the Process Industries by Peter L. King Pdf
Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.