LEAN FOR THE PROCESS INDUSTRIES DEALING WITH COMPLEXITY

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Lean For The Process Industries

Author : Peter L. King
ISBN : UOM:39076002810526
Genre : Business & Economics
File Size : 39.65 MB
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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.
Category: Business & Economics

Value Stream Mapping For The Process Industries

Author : Peter L. King
ISBN : 9781482247695
Genre : Business & Economics
File Size : 58.29 MB
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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.
Category: Business & Economics

Lean Supply Chain Planning

Author : Josef Packowski
ISBN : 9781482205343
Genre : Business & Economics
File Size : 81.14 MB
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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.
Category: Business & Economics

Lean Pedagogy

Author : Benjamin Chibaira
ISBN : 9781483559704
Genre : Education
File Size : 77.86 MB
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In this book, the author introduces the academic world to the concept of Lean Thinking. Although Lean is popular in industry and commerce, having brought tremendous improvements in product and service quality as well as reducing costs and process times, it has barely made inroads into schools. The author takes readers through a journey of why it is important to consider Lean as an alternative to resolving the current issues in classrooms. A case study that was done over a several years within a school environment to test the principles and tools is detailed, including the results and the inferences made out of them. A checklist to asses a school's preparedness for a Lean roll-out as well as a typical implementation plan and models is included.
Category: Education

The Product Wheel Handbook

Author : Peter L. King
ISBN : 9781466554191
Genre : Business & Economics
File Size : 27.25 MB
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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.
Category: Business & Economics

Liquid Lean

Author : Raymond C. Floyd
ISBN : 1420088637
Genre : Business & Economics
File Size : 22.15 MB
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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.
Category: Business & Economics

From Complexity To Simplicity

Author : S. Collinson
ISBN : 9781137006226
Genre : Business & Economics
File Size : 35.21 MB
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Complexity is slowing companies down, costing them on average 10% of their profits. Based on cutting-edge research, this practical 'how to' guide will show businesses how to remove complexity to boost profits and morale.
Category: Business & Economics

Out Of The Present Crisis

Author : Terence T. Burton
ISBN : 9781466566866
Genre : Business & Economics
File Size : 70.86 MB
Format : PDF, Kindle
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Today, organizations have achieved an overall failure rate above 80 percent with Lean, Six Sigma, Lean Six Sigma, and continuous improvement in general. This is certainly not due to a shortage of books, consultants, and other online resources about the methodologies and tools, or the success stories of Toyota and others. However, it is due to a shortage of knowledge and practice about the most critical success factors of improvement: leadership, sustaining infrastructure, behavioral and cultural transformation, and now emerging technology. These factors produce 90 percent of the success with continuous and sustainable improvement; the methodologies and tools represent an irrelevant 10 percent. For decades, most organizations have focused on this quick and easy, irrelevant 10 percent through an endless series of fad, in-vogue improvement programs as they attempt to mimic the best-in-class practices of the most successful organizations. Out of the Present Crisis: Rediscovering Improvement in the New Economy is the contemporary version of Deming’s famous 1982 book, "Out of the Crisis." The author builds a solid case for organizations to aggressively pursue the next generation of systematic and sustainable improvement through a combined strategy of Deming’s back-to-basics, innovation and breakthrough thinking, integration of emerging and enabling technology, and adaptive improvement across diverse environments and industries. The book’s practical, pragmatic style is backed up by many real world examples and personal experiences. If you're looking for another book about Lean or Six Sigma "tools" this is not it. But it is a book about how to achieve lasting success by making improvement the cultural standard of excellence and living code of conduct in organizations. This popular book provides executives with an up-to-date and proven reference guide for rediscovering successful systematic and sustainable improvement in today’s economy. The author demonstrates the importance of viewing improvement as a continuous manageable "process" and covers the most critical success factors of leadership, sustaining infrastructure, behavioral and cultural transformation, and emerging technology in a practical, no-nonsense, "how-to-do" style. The book provides specific guidance for all industries including public and private corporations, hospitals, financial services, airlines, municipalities, and federal, state, and local governments.
Category: Business & Economics

Product Lifecycle Management To Support Industry 4 0

Author : Paolo Chiabert
ISBN : 9783030016142
Genre : Business & Economics
File Size : 71.78 MB
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This book constitutes the refereed post-conference proceedings of the 15th IFIP WG 5.1 International Conference on Product Lifecycle Management, PLM 2018, held in Turin, Spain, in July 2018. The 72 revised full papers presented were carefully reviewed and selected from 82 submissions. The papers are organized in the following topical sections: building information modeling; collaborative environments and new product development; PLM for digital factories and cyber physical systems; ontologies and data models; education in the field of industry 4.0; product-service systems and smart products; lean organization for industry 4.0; knowledge management and information sharing; PLM infrastructure and implementation; PLM maturity, implementation and adoption; 3D printing and additive manufacturing; and modular design and products and configuration and change management.
Category: Business & Economics

Visual Studio Team Foundation Server 2012

Author : Sam Guckenheimer
ISBN : 9780133119183
Genre : Computers
File Size : 30.69 MB
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Use Visual Studio® Team Foundation Server 2012 and Agile Methods to Deliver Higher Value Software Faster This is the definitive guide to applying agile development and modern software engineering practices with Visual Studio Team Foundation Server 2012—Microsoft’s complementary Application Lifecycle Management (ALM) platform. Written by the Microsoft Visual Studio product owner and a long-time Team Foundation Server implementation specialist, it focuses on solving real development challenges, systematically eliminating waste, improving transparency, and delivering better software more quickly and painlessly. Coverage includes • Accelerating the “flow of value” to customers, with a transparent backlog, PowerPoint Storyboarding, VS 2012 feedback requests, and a “usability lab” right into your customers’ hands • Driving quality upstream to uncover hidden architectural patterns, ensure cleaner code, fix multiple recurring “cloned” bugs at once, ensure the definition of done with continuous integration and deployment in a reliable build process • Eliminating “no repro” bugs with VS 2012’s six powerful mechanisms for more accurate fault identification and use of virtualized test environments • Using Scrum or other Agile methods with Process Templates effectively across distributed teams in large organization by automating burndowns and dashboards to identify “early warning signals” of emerging problems with quality or maintainability • Staying in the groove by storing the state of your work and environment with shelvesets, to let you handle interruptions smoothly • Leveraging VS 2012’s new support for multiple Microsoft and open source unit testing frameworks in your IDE and continuous integration pipeline • Performing exploratory testing to uncover bugs in surprising places and testing immersive Windows 8 apps • Rapidly improving team development and collaboration with the hosted Team Foundation Service Whatever your development role, this book will help you apply modern software development practices using Visual Studio Team Foundation Server 2012 to focus on what really matters: building soft­ware that begins delivering exceptional value sooner and keeps delighting customers far into the future.
Category: Computers