New Manufacturing Challenge: Techniques for Continuous Improvement

Author:   Kiyoshi Suzaki
Publisher:   Simon & Schuster
ISBN:  

9781451697551


Pages:   260
Publication Date:   09 May 2012
Format:   Paperback
Availability:   Available To Order   Availability explained
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New Manufacturing Challenge: Techniques for Continuous Improvement


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Overview

As a consultant, Kiyoshi Suzaki has helped scores of Fortune 500 clients improve manufacturing operations and get the job done faster, cheaper, better, and safer. Now, in this detailed ""operating manual"" -- full of more step-by-step applications than any other book available -- Suzaki spells out new options in production and employee resources that can help American industry regain the cutting edge in price, quality, and delivery of products. A well-known expert in the field, Suzaki begins with the premise that ""if it doesn't add value, it's waste"" -- a concept devised by Henry Ford and later used by Toyota. He recaps what Toyota identifies as the seven most prominent forms of waste in factories. Most importantly, he meticulously details steps individuals can take to ""simplify, combine, and eliminate operations"" -- thereby reducing waste, improving quality, and saving money. Describing in detail the basic techniques culled from Japanese industrial philosophy and procedure, Suzaki shows how small, family-run businesses and billion-dollar American corporations from a wide range of industries -- automotive, electronics, cosmetics, and even defense contractors -- are meeting the manufacturing challenge today -- demolishing the widely held belief that most American manufacturers have become distribution organizations for products manufactured overseas. In addition, he links his methodology with several successful production systems, from Just-In-Time Production, Total Quality Control, Total Productive Maintenance to Computer Integrated Manufacturing. Throughout this practical handbook, he places emphasis squarely on the shop floor and grounds his approach in easy, yet powerful techniques everybody can understand and implement today. Illustrated with numerous charts and exhibits, The New Manufacturing Challenge shows how to integrate people and techniques to improve the workplace and, thus, strengthen any company's competitiveness in the global marketplace.

Full Product Details

Author:   Kiyoshi Suzaki
Publisher:   Simon & Schuster
Imprint:   The Free Press
Dimensions:   Width: 15.60cm , Height: 1.80cm , Length: 23.40cm
Weight:   0.350kg
ISBN:  

9781451697551


ISBN 10:   1451697554
Pages:   260
Publication Date:   09 May 2012
Audience:   General/trade ,  General
Format:   Paperback
Publisher's Status:   Active
Availability:   Available To Order   Availability explained
We have confirmation that this item is in stock with the supplier. It will be ordered in for you and dispatched immediately.

Table of Contents

Preface Acknowledgments Introduction 1. Eliminating Waste SCENES IN THE FACTORY WASTE SIMPLIFY, COMBINE, AND ELIMINATE 2. Back-to-Basics Discipline HOUSEKEEPING IMPROVEMENTS WORKPLACE ORGANIZATION 3. Meeting Diversified Customer Needs with Quick Setup SETUP TIME REDUCTION TECHNIQUES FOR QUICK SETUP 4. Developing Flow on the Production Floor FROM PROCESS-ORIENTED LAYOUT TO PRODUCT-ORIENTED LAYOUT MACHINE UTILIZATION VERSUS ON-DEMAND UTILIZATION 5. Expanding Skills for Increased Flexibility MULTIPROCESS HANDLING SKILL DEVELOPMENT AND JOB ROTATION 6. Improving Processes for Productivity Gains PRINCIPLES FOR PROCESS IMPROVEMENT U-SHAPED LINES PROCESS ANALYSIS FOR MULTIPLE VARIETIES OF ITEMS APPROACHES TO PROCESS IMPROVEMENT 7. Strengthening Our Nerves and Muscles JIDOKA (AUTONOMATION) LINE STOP CONCEPT ANDON (TROUBLE LIGHTS) PRODUCTION CONTROL BOARDS POKA-YOKE (FOOLPROOF MECHANISMS) QUALITY AT THE SOURCE VISUAL CONTROL 8. Aiming for Zero Machine Trouble PREVENTIVE MAINTENANCE TOTAL PRODUCTIVE MAINTENANCE 9. Scheduling a Steady Flow for Better Control LEVELED/MIXED PRODUCTION CYCLE TIME CONTROL 10. Improving with Standards STANDARD WORK WORK COMBINATION CHART 11. Tying Things Together KANBAN PRODUCTION CONTROL SYSTEM 12. Redefining the Roles of Conveyors and Transportation CONVEYORS TRANSPORTATION 13. Suppliers as Extended Factories NEW SUPPLIER RELATIONSHIPS 14. Developing Co-Destiny with Employees JOB SECURITY IMPROVEMENT THROUGH PEOPLE 15. Eliminating Problems at the Organizational Boundaries TOTAL OPTIMIZATION AND LOCAL OPTIMIZATION ORGANIZATIONAL STRUCTURE FOLLOWS ECONOMIC NEED 16. People Make It Happen CENTRALIZED AND DECENTRALIZED ORGANIZATION OWNERSHIP, OWNERSHIP, OWNERSHIP PEOPLE MAKE IT HAPPEN 17. Establishing a Competitive Position THE FACTORY AS ORCHESTRA INTEGRATION GETTING STARTED GUIDED AUTONOMY WHAT IS MANUFACTURING STRATEGY? THE NEW MANUFACTURING CHALLENGE Epilogue: Vision of the Future Bibliography Index

Reviews

J. Richard Iverson President and CEO, American Electronics Association Mr. Suzaki develops basic manufacturing approaches that will truly challenge the perceptive manager.


John L. Warne Former President and COO, Omark Industries An excellent resource for operating managers who want to bring their manufacturing up to world class. Lewis E. Platt Senior Vice President, Hewlett-Packard Company It's packed with examples which reinforce techniques for continuous improvement and stir the reader to action. It also helps us develop a common understanding of how to restore our competitive edge. Brian Kelley Plant Manager, Cummins Engine Company Suzaki's book is a practitioner's book -- not another theory book. Tom Peters Co-author of In Search of Excellence and A Passion for Excellence Continuous improvement, with everyone involved, must become the American norm -- or else. We must shed 150 years of wrong-headed thinking. Kiyoshi Suzaki makes an important contribution to our doing just that. Leonard J. Ricard Director-Inventory Management and Methods, General Motors Corporation This book is filled with practical techniques for improving quality and productivity together with scores of examples of the application of those techniques. It is a valuable handbook for all who must meet today's competitive manufacturing challenges. Leonard A. Harvey Executive Vice President, Borg-Warner Corporation ...this book cuts through a lot of the mystique in modern manufacturing...it demonstrates, in a concise manner, the perceptions needed to make today's factory competitive. Shoichi Saba Chairman and CEO, Toshiba Corporation Suzaki describes the core of Japanese manufacturing techniques...this simple yet very insightful work should be shared by business leaders and practitioners around the world. Kenneth L. Thorpe Executive Vice President, Society of Manufacturing Engineers Every manufacturing manager and top executive should read this book to learn how they can gain an advantage over their competition through discipline, involvement and common sense. Robert W. Hall Professor of Operations Management, Indiana University School of Business Readers unfamiliar with the new production will find the book an easily read explanation of Japanese 'techniques...Experienced readers will find a great blend of current Japanese and American thinking. J. Richard Iverson President and CEO, American Electronics Association Mr. Suzaki develops basic manufacturing approaches that will truly challenge the perceptive manager.


Brian Kelley Plant Manager, Cummins Engine Company Suzaki's book is a practitioner's book -- not another theory book. J. Richard Iverson President and CEO, American Electronics Association Mr. Suzaki develops basic manufacturing approaches that will truly challenge the perceptive manager. John L. Warne Former President and COO, Omark Industries An excellent resource for operating managers who want to bring their manufacturing up to world class. Kenneth L. Thorpe Executive Vice President, Society of Manufacturing Engineers Every manufacturing manager and top executive should read this book to learn how they can gain an advantage over their competition through discipline, involvement and common sense. Leonard A. Harvey Executive Vice President, Borg-Warner Corporation ...this book cuts through a lot of the mystique in modern manufacturing...it demonstrates, in a concise manner, the perceptions needed to make today's factory competitive. Leonard J. Ricard Director-Inventory Management and Methods, General Motors Corporation This book is filled with practical techniques for improving quality and productivity together with scores of examples of the application of those techniques. It is a valuable handbook for all who must meet today's competitive manufacturing challenges. Lewis E. Platt Senior Vice President, Hewlett-Packard Company It's packed with examples which reinforce techniques for continuous improvement and stir the reader to action. It also helps us develop a common understanding of how to restore our competitive edge. Robert W. Hall Professor of Operations Management, Indiana University School of Business Readers unfamiliar with the new production will find the book an easily read explanation of Japanese 'techniques...Experienced readers will find a great blend of current Japanese and American thinking. Shoichi Saba Chairman and CEO, Toshiba Corporation Suzaki describes the core of Japanese manufacturing techniques...this simple yet very insightful work should be shared by business leaders and practitioners around the world. Tom Peters Co-author of In Search of Excellence and A Passion for Excellence Continuous improvement, with everyone involved, must become the American norm -- or else. We must shed 150 years of wrong-headed thinking. Kiyoshi Suzaki makes an important contribution to our doing just that.


Tom Peters Co-author of In Search of Excellence and A Passion for Excellence Continuous improvement, with everyone involved, must become the American norm -- or else. We must shed 150 years of wrong-headed thinking. Kiyoshi Suzaki makes an important contribution to our doing just that. Leonard J. Ricard Director-Inventory Management and Methods, General Motors Corporation This book is filled with practical techniques for improving quality and productivity together with scores of examples of the application of those techniques. It is a valuable handbook for all who must meet today's competitive manufacturing challenges. Shoichi Saba Chairman and CEO, Toshiba Corporation Suzaki describes the core of Japanese manufacturing techniques...this simple yet very insightful work should be shared by business leaders and practitioners around the world. Kenneth L. Thorpe Executive Vice President, Society of Manufacturing Engineers Every manufacturing manager and top executive should read this book to learn how they can gain an advantage over their competition through discipline, involvement and common sense. J. Richard Iverson President and CEO, American Electronics Association Mr. Suzaki develops basic manufacturing approaches that will truly challenge the perceptive manager. John L. Warne Former President and COO, Omark Industries An excellent resource for operating managers who want to bring their manufacturing up to world class. Lewis E. Platt Senior Vice President, Hewlett-Packard Company It's packed with examples which reinforce techniques for continuous improvement and stir the reader to action. It also helps us develop a common understanding of how to restore our competitive edge. Brian Kelley Plant Manager, Cummins Engine Company Suzaki's book is a practitioner's book -- not another theory book. Leonard A. Harvey Executive Vice President, Borg-Warner Corporation ...this book cuts through a lot of the mystique in modern manufacturing...it demonstrates, in a concise manner, the perceptions needed to make today's factory competitive. Robert W. Hall Professor of Operations Management, Indiana University School of Business Readers unfamiliar with the new production will find the book an easily read explanation of Japanese 'techniques...Experienced readers will find a great blend of current Japanese and American thinking.


Author Information

Kiyoshi Suzaki is president of The Eucalyptus Group in Pacific Palisades, California and an internationally recognized consultant on manufacturing competitiveness in various industries in the United States, Europe, and the Far East. Besides consulting, he lectures in major universities, serves on the board of directors of several U.S. companies and as an advisor to Japan Technology Transfer Association. Mr. Suzaki is author and co-author of two books on manufacturing published in Japan and France.

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