Made to Order LeanExcelling in a High Mix, Low Volume Environment
By: Greg Lane
Foreword by: John Shook
Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in Job Shops (high-mix, low volume manufacturing & service businesses).
While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in these job shop environments.
Made to Order Lean is specifically geared to manufacturer's and service companies that have 100's to 1,000's of active part numbers or services with little or no forecasting. The primary focus is on eliminating non-value added & adapting the culture, parts are separated into runners, repeaters & strangers (ABC analysis) and managed differently.
The workbook is:
- Based on Toyota Methodology & explains how to adapt to high-mix, low volume.
- Fully illustrated with actual examples & photos from successful applications.
- Includes an implementation flow chart for job shops and allows you to customize your transformation.
- Written in a simple & logical fashion by a former Toyota employee & job shop owner with 20 years experience.
Foreword by John Shook
Introduction: Method & Overview
Ch. 1: Managing Visually
Ch. 2: Management Auditing: Standardized Work for Managers
Ch. 3: Associating a Time with All Work
Ch. 4: Utilizing Day by Hour & FIFO Boards
Ch. 5: Making Improvements When You're Short of Capacity
Ch. 6: Making Improvements When You Have Excess Capacity
Ch. 7: Using Value Stream Mapping in a Low Volume Environment
Ch. 8: Making Man Power Improvements
Ch. 9: Improving Machine Performance & Plant Layout
Ch. 10: Making Improvements through Office Department Kaizen
Ch. 11: Making Improvements through Office Process Kaizen
CH. 12: Improving Your Product Costing
Glossary
Index
About the Author
Praise for Made-to-Order-Lean
"This book is an excellent resource for applying lean principals to the complex topic of high-mix, low-volume manufacturing, and is core reading material for those implementing a lean system in this environment"
Paul A. Brent General Director - Global Supplier
Quality & Development, Delphi Corporation
"Made-to-Order-Lean provides clear and practical insights into how to increase competitiveness of a manufacturing facility. It will teach you how to increase the productivity of your operations through proper visual aides, improve quality and satisify today's demanding customers."
Lee C. Banks, Senior Vice President & Operating
Officer, Parker Hannifin Corporation
To purchase this book click on Productivity Press's link:
By: Greg Lane
Can lean improvements alone really dramatically grow and improve a company’s profitability? Read the true story of someone armed with only his lean background and no experience in the particular industry, that purchased an already profitable manufacturing business, grew it and then profitably sold it. The author who was trained in lean ideologies by Toyota purchased a CNC machining and assembly company even though he had never worked or operated a similar type of machine or business in his life.
Learn his transformation methodology through this interesting tale of what ideas worked and those that failed, learn the steps to buying a small business and laugh at how he overcame some of the hurdles. Find out how lean methods helped to develop and grow the company into new markets and expand the production capabilities. Get to know the employees and their fear of change and what was done to overcome it. Understand how not only the shop floor required continuous improvements, but see where and how the front office was also transformed. You will see that all of these ideas do not only apply in large industries but also work in job shop environments where products are “made to order”.
You will be compelled to read on as the author must first learn every operation before he can gain the respect to lead change. Major learning points are highlighted throughout the book while details of the methodologies are captured in the appendix. You are sure to find this a great read and come away with more ideas and a methodology to try in your own environment. Learning in a non-fictional format is sure to inspire while also containing the realities of the failures and the respective lessons that were learned.
Table of contents
Preface
Prologue: The Purchase
Ch. 1: The Beginning - Observation & Documentation
Ch. 2: Standardizing the Estimating Process
Ch. 3: Learning the Office Processes
Ch. 4: The First Days Alone
Ch. 5: Creating Capacity & Selling It
Ch. 6: Getting Everyone Motivated for Improving the Machine's Output
Ch. 7: Seeing the Administrative Process from a New Angle
Ch. 8: Moving the Business
Ch. 9: Accurate Pricing Through Better Cost Allocations
Ch. 10: Upfront Delays
Ch. 11: Making Money During the Good Times
Ch. 12: Expanding Into New Products
Ch. 13: Business For Sale
Ch. 14: Reflections
Appendices (examples of improvements)
Praise for Mr. Lean Buys & Transforms a Mfg. Co.:
“This intriguing story
proves beyond a doubt that lean principals go a long way towards profitability
for all of us. Assuming you subscribe to “management” being synonymous with
“improvement”, you are sure to come away from this book with a clear plan for trialing
a few new improvements”.
Xavier Pujol
Plant and Site Manager
Continental Corporation
It is a fun read. If you’ve
ever considered how you would go about transforming your own manufacturing enterprise
or if you own such an enterprise that needs transformation – this book will
definitely provide thought-provoking ideas and some guiding principles along
with specific hints for dealing with challenges that your company faces today.
John Shook, Former Toyota
Manager, November 2009
Worldwide you can order direct from CRC-Productivity Press:
