Lean Manufacturing

Introduction: Five Stages of Lean Manufacturing Lean Manufacturing Industrial Dynamics and Bullwhip Effect Three Toolboxes for Lean Manufacturing Let's Play a "Lean" Game: Manufacturing a Gyrocopter Five Stages of Lean Manufacturing: Business Bottom-Line Based Put Business Bottom Line First: Transfer Function for Production Cost Production Transfer Function Short-Term vs. Long-Term Production Transfer Functions Short-Term Transfer Function for Production Transfer Function for Marginal Cost The Law of Diminishing Returns: Key to Understanding Lean Manufacturing Transfer Function for Average Fixed Cost Transfer Function for Average Variable Cost Transfer Function for Average Total Cost Transfer Function for Long-Term Cost Analysis Goal Tree and Success Analysis: From Goal Setting to Successful Goal Setting Understanding the Voice of Customers: The Essential Elements Voice of Customers: Relentlessly Customer Focused Voice-of-Customers Capability: Critical Elements Voice of Customers' Role and Responsibilities Analyzing Voice of Customers: Law of Demand Maximizing Utility to Customers Kano Model: Integrate the Elements for Voice of Customers Balance Production and Demand: Value Stream Mapping What Are Value Streams? What Is Value Stream Mapping? How to Complete Value Stream Mapping Guidelines for Developing Value Stream Mapping Kaizen Event Analysis for Value Stream Mapping Business Bottom-Line Analysis of Value Streams From Lognormal to Cobb--Douglas Distribution: Lean Production Analysis Technology: The Production Function Long-Run and Short-Run Production Functions Three Stages of Production Lognormal Distribution Cobb--Douglas Production Function Quantifying Additional Profit from Productivity Gains Total Factor Productivity Business Cycles and Demand Fluctuations: Time-Critical Analysis and Decision Making Business Cycles and Demand Fluctuations Regression Analysis: Understanding Customer Demand Statistically What Is Time Series Analysis? Smoothing Techniques Summary How Demand Fluctuation and "Exogenous Shocks" Influence the Bottom Line How To Shockproof Your Company: A Lesson from Frank Lloyd Wright Business Risk Assessment Risk Quadrant Chart Develop a Business Risk Management Plan Risk Assessment Matrix Lean Production: Business Bottom-Line Based Approach for Identifying Productivity Improvements Quantifying Additional Profit from Productivity Gains Case Study of a Gyrocopter Manufacturer: Improving Profitability Implement Cellular Manufacturing Example of Cellular Manufacturing: Organize Gyrocopter Production Equipment into Cells to Reduce Inventory and Process Time Example of Gyrocopter Manufacturing: Eliminate Intermediate Spooling Operation Manage Production and Inventory Costs Theory of Constraints: "The Drum Is a Bottleneck" Identifying and Exploring Constraints The Five Focusing Steps and the Continuous Improvement Goal The General Application of Theory of Constraints to Operations: Drum--Buffer--Rope Approach Plant Types for Operations The Thinking Processes for Implementing Theory of Constraints Learning as Actively Addressing Constraints Learning to Negotiate the Meaning of Constraints Accounting Systems for Lean Manufacturing Case Study: Marion Gyrocopter Corporation (MGC) Conclusion about the Case Study Kanban: Align Manufacturing Flow with Demand Pull Kanban-Based Systems Why Use Kanban? How Kanban Works The Rules for Kanban Steps for Implementing Kanban Types of Kanban Kanban Development Kanban Design to Achieve Manufacturing System Objectives Kanban Card Calculation Summary Jidoka: Implement Lean Manufacturing with Automation What Is Jidoka? Ladder Logic: A Tool to Implement Jidoka Boolean Functions for Ladder Logic Implement Jidoka Using Ladder Logic Additional Functionality for Manufacturing Autonomation Pull System, One-Piece Flow, and Single Minute Exchange of Die (SMED) Establish a Pull System Why Use Pull Systems and One-Piece Flow? Overcome Barriers: Two Old Beliefs Single Minute Exchange of Die (SMED) How to Implement Single Minute Exchange of Die (SMED) Case Study: Flow Management of an Integrated Circuit Packaging Work-in-Process System Lean Manufacturing Business Scorecards What Are Lean Manufacturing Business Scorecards? How Have Lean Manufacturing Business Scorecards Been Evolved? Lean Manufacturing Business Scorecard for Planning and Policy Deployment Lean Manufacturing Business Scorecards for Problem Solving and Continuous Improvement Building the Business Intelligence Strategy Bibliography Index