Lean for the Process Industries: Dealing with Complexity, Second Edition, 2nd Edition (Hardback) book cover

Lean for the Process Industries

Dealing with Complexity, Second Edition, 2nd Edition

By Peter L. King

Productivity Press

336 pages | 150 Color Illus.

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Hardback: 9780367023324
pub: 2019-06-17
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Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While, a number of innovators have successfully applied Lean principles to these industries over the last two 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, 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 systemically eliminate them.
  • Provides process-oriented modifications that will enhance the usefulness of Cellular Manufacturing, Heijunka Production Leveling, and Pull Replenishment Systems.
  • Discusses the role of process operations management in a Lean strategy

Whether you are manufacturing consumer products such as foods, paints, and pharmaceuticals, or materials such as bulk chemicals, sheet goods, and synthetic fibers, this book shows you how to achieve that enviable level of performance where continual improvement becomes inherent to your processes.

Table of Contents

Introduction: Lean Overview The Process Industries: what makes them unique Value Stream Mapping the Process Industries The Basics: Kaizen Events The 8 Wastes in the Process Industries Set-up reduction & SMED Total Productive Maintenance Visual Management Dealing with Complexity: Finding, managing, and improving Bottlenecks Cell design in the Process Industries Production scheduling, production sequencing, production leveling: Product Wheels Lead time improvement Postponement: Finish-to-Order Pull Systems Supermarket design Fixed interval replenishment Fixed quantity replenishment Managing variability: Safety Stock Creating the Future State Map The importance of robust business processes Appendix: The Hypothetical Process description and data

About the Author

Peter L. King is the president of Lean Dynamics, LLC, a manufacturing improvement consulting firm located in Newark, Delaware. Prior to founding Lean Dynamics, Pete spent 42 years with the DuPont Company, in a variety of control systems, manufacturing systems engineering, Continuous Flow Manufacturing, and Lean Manufacturing assignments. That included 18 years applying Lean Manufacturing techniques to a wide variety of products, including sheet goods like DuPont™ Tyvek®, Sontara®, and Mylar®; fibers such as nylon, Dacron®, Lycra®, and Kevlar®; automotive paints; performance lubricants; bulk chemicals; adhesives; electronic circuit board substrates; and biological materials used in human surgery. On behalf of DuPont, Pete has consulted with key customers in the processed food and carpet industries. Pete retired from DuPont in 2007, leaving a position as Principal Consultant in the Lean Center of Competency. Recent clients have included producers of sheet goods, lubricants and fuel additives, vitamins and nutritional supplements, and polyethylene and polypropylene pellets.

Pete received a bachelor’s degree in Electrical Engineering from Virginia Tech, graduating with honors. He is Six Sigma Green Belt certified (DuPont, 2001), Lean Manufacturing certified (University of Michigan, 2002), and is a Certified Supply Chain Professional (APICS, 2010). He is a member of the Association for Manufacturing Excellence, APICS, and the Institute of Industrial Engineers.

He served as president of IIE’s Process Industry Division in 2009–2010. Pete is the author of Lean for the Process Industries—Dealing with Complexity (Productivity Press, 2009), and several published articles on the application of Lean concepts to process operations. He is the co-author of The Product Wheel Handbook—Creating Balanced Flow in High Mix Process Operations

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Production & Operations Management
SCIENCE / Chemistry / Industrial & Technical