1st Edition

Beyond Lean Production Emphasizing Speed and Innovation to Beat the Competition

By Roger G. Lewandowski Copyright 2014
    108 Pages 24 B/W Illustrations
    by Productivity Press

    108 Pages
    by Productivity Press

    It is estimated that U.S. manufacturers are currently operating at only 65 percent effectiveness in implementing Lean production. Covering the fundamentals needed to be competitive in today’s marketplace, Beyond Lean Production: Emphasizing Speed and Innovation to Beat the Competition provides readers with the tools to help their organizations achieve 100 percent effectiveness in Lean production.

    Explaining that overseas factories can't compete with U.S. factories in speed of delivery to domestic customers, the book provides the understanding required to add speed and urgency in all that you do in the office and the factory. It explains how to eliminate waste so you can meet and even exceed your customers’ expectations regarding service, quality, and cost.

    The book is organized into two phases. The first phase, Holding Actions, covers the fundamentals needed to hold your position against the competition until you can implement the methods described in phase II of the book. It presents 12 little-known tools and strategic weapons that you can immediately put to use to improve on your current competitive position. Phase II, The Business Command Center, presents unique and powerful concepts that can be used with the fundamentals covered in phase I.

    Explaining how to use speed as a competitive weapon, the book will help you to remove the obstacles that interfere with continuous flow manufacturing. It presents the concept of circulatory management that can put a stop to the ever-increasing layers of management with decreasing ownership.

    By implementing the holding action and the business command center described in this book, you can significantly improve your odds of beating the competition at home and overseas.

    Introduction

    Phase 1 Holding Actions
    Introduction
    Highlights of Key Items
    Holding Action First
    Tool 1: Continuous Flow Manufacturing
    Tool 2: High-Velocity Working Capital
    Tool 3: Process Utilization: Total Team Game Plan
    Tool 4: Pull Systems
         Push Your Production Forecast out the Door and Pull in Customer Satisfaction
    Tool 5: Root Cause Analysis
    Tool 6: Single-Minute Exchange of Dies
    Tool 7: Strategic Business Units 
         An Old Idea Updated Makes Sense: Saves People, Space, and Overhead 
         Important Points 
         Conclusion
    Tool 8: Zero-Based Process Mapping 
         Ten Steps to Process Mapping
    Tool 9: Strategic Kanbans
    Tool 10: Accelerated Return on Kaizen (ARK) 
         Necessity Is the Mother of Invention 
         Summary
    Tool 11: Supply Chain Management
    Tool 12: Inventory Turns Control 
         A Items 
         B Items
         C Items
    Tool 13: Mall Theory
    Summary for Phase 1: Holding Actions

    Phase 2 The Business Command Center
    Introduction to the Business Command Center
         Bold Breakthrough that Will Make You Rethink Your Leadership
    The Business Command Center
         What Is a Business Command Center?
         Implementing the Business Command Center
         Key Points of the Circulatory Management Chart
         Special Points
         Circulatory Management
         Business Command Center: Leadership
         How Do You Organize Control of the Command Center?
         Summary
    What Are the Benefits of Having a Business Command Center?
    Future Possibilities
         Field Sales Organization
         Distribution Centers
    Closing Thoughts
    Further Information and Homework
    Advanced Value Stream Mapping
    Accounting: The Dictators of Corporations or Forgotten Priests? What Should Its Role Be?
    U.S. Product Engineering: Is It a Misdirected Missile as It Is Now Organized?
    Industrial Engineering: The Forgotten Function?

    Index

    Biography

    Roger G. Lewandowski