1st Edition
The Portal to Lean Production Principles and Practices for Doing More with Less
342 Pages
113 B/W Illustrations
by
Auerbach Publications
344 Pages
by
Auerbach Publications
Also available as eBook on:
The Portal to Lean Production: Principles and Practices for Doing More with Less describes the steps, difficulties, and rewards of implementing lean production. The book moves beyond concepts to address practical matters. The authors provide enough information for you to begin implementing lean production within your organization. This book applies a model-the Portal to Lean Production-to... Read more
Portal to Lean Production
Race with a Moving Finish Line
Awakening to Lean Production
The Portal
The Organization of the Book
THE JOURNEY, FIRST STEPS
Beginnings
Toyota Production System
Quick History of TPS
TPS and the Portal to Lean Production
First Glimpse of a Manufacturing Cell
The Indiana Plant
Cellular Manufacturing
Throughput and Quality
Gaining Experience, Broadening the Concept
Trap Cell
Scheduling for Uniform Load
Cell Design
Applying the Cell Concept Plantwide
The Revelation
Linked Workcells and Subcells
Implementation
BUILDING UP STEAM
Kanban
Inventory Mess
Adopting Pull Production
Pull-Production Concepts
Number of Kanbans
Signal and Control: Methods and Issues
Total Productive Maintenance
Breakdown in the Trap Cell
Concepts of Maintenance Management
Preventive Maintenance
Total Productive Maintenance
Quick Changeover
A Tale of Two Plants
Setup Reduction Concepts and Techniques
SMED Procedure
Techniques for Setup Reduction
Checklist
Attachments and Fasteners
Eliminate Adjustments
Storage
Carts
Setup-Reduction Projects
Component of a Larger System
Standard Work
Strange-Looking Charts
Concept of Standard Work
What Is Standard Work?
Critical Role in Kaizen
Focused Factories
Early Focused-Factory Experience
Focused-Factory Team Leaders
A Little Knowledge Can Be…
Clash of the Old and the New
Focused Factory
Microdesign Issues
Clustering Products and Operations
Focused-Factory Organization
Customer-Focused Quality
Listening to Your Customers
Customer Complaint
Statistical Variation
Experimentation
Awakening
Road to Six Sigma
Quality Assurance in Lean Production
Problem-Solving Tools
Statistical Process Control
Nonstatistical Process Control
Quality at the Source
Quality Improvement and TPS
SUSTAINING MOMENTUM
Employee Involvement, Workplace Organization, Kaizen
Employee Involvement and Workplace Organization
Value Stream Mapping
Main Vent Assembly Cell
Supply-Chain Partnerships
Learning from Our Suppliers
Problems with Parts
Building Bonds with a Supplier
Building Bonds in the Supply Chain
Supply-Chain Concept
The Lean Supply Chain
Partner Relationships
Little Customer, Big Supplier
This Can Be Difficult
The Lean Enterprise
Product Design
Lean Product Development
Process Engineering
Purchasing Function
Accounting and Finance
Sales and Marketing
Human Resources
Lean Culture Transformation
Organization Culture
Role of Management
Sustaining Momentum
Transformational Leadership
Mistakes
Closing Thoughts
APPENDIX A: Glossary
Race with a Moving Finish Line
Awakening to Lean Production
The Portal
The Organization of the Book
THE JOURNEY, FIRST STEPS
Beginnings
Toyota Production System
Quick History of TPS
TPS and the Portal to Lean Production
First Glimpse of a Manufacturing Cell
The Indiana Plant
Cellular Manufacturing
Throughput and Quality
Gaining Experience, Broadening the Concept
Trap Cell
Scheduling for Uniform Load
Cell Design
Applying the Cell Concept Plantwide
The Revelation
Linked Workcells and Subcells
Implementation
BUILDING UP STEAM
Kanban
Inventory Mess
Adopting Pull Production
Pull-Production Concepts
Number of Kanbans
Signal and Control: Methods and Issues
Total Productive Maintenance
Breakdown in the Trap Cell
Concepts of Maintenance Management
Preventive Maintenance
Total Productive Maintenance
Quick Changeover
A Tale of Two Plants
Setup Reduction Concepts and Techniques
SMED Procedure
Techniques for Setup Reduction
Checklist
Attachments and Fasteners
Eliminate Adjustments
Storage
Carts
Setup-Reduction Projects
Component of a Larger System
Standard Work
Strange-Looking Charts
Concept of Standard Work
What Is Standard Work?
Critical Role in Kaizen
Focused Factories
Early Focused-Factory Experience
Focused-Factory Team Leaders
A Little Knowledge Can Be…
Clash of the Old and the New
Focused Factory
Microdesign Issues
Clustering Products and Operations
Focused-Factory Organization
Customer-Focused Quality
Listening to Your Customers
Customer Complaint
Statistical Variation
Experimentation
Awakening
Road to Six Sigma
Quality Assurance in Lean Production
Problem-Solving Tools
Statistical Process Control
Nonstatistical Process Control
Quality at the Source
Quality Improvement and TPS
SUSTAINING MOMENTUM
Employee Involvement, Workplace Organization, Kaizen
Employee Involvement and Workplace Organization
Value Stream Mapping
Main Vent Assembly Cell
Supply-Chain Partnerships
Learning from Our Suppliers
Problems with Parts
Building Bonds with a Supplier
Building Bonds in the Supply Chain
Supply-Chain Concept
The Lean Supply Chain
Partner Relationships
Little Customer, Big Supplier
This Can Be Difficult
The Lean Enterprise
Product Design
Lean Product Development
Process Engineering
Purchasing Function
Accounting and Finance
Sales and Marketing
Human Resources
Lean Culture Transformation
Organization Culture
Role of Management
Sustaining Momentum
Transformational Leadership
Mistakes
Closing Thoughts
APPENDIX A: Glossary
Biography
John Nicholas, Avi Soni
