Improving Production with Lean Thinking encompasses the science and analytical background for improving manufacturing, control, and design.

Features:

• Material flow and facilities layout, including a six step layout design process
• The design of cellular layouts
• Analyzing and improving equipment efficiency, including Poka-Yoke, motion study, maintenance, SMED, and more
• Environmental improvements, including 5S implementation

Contents

Continuous improvement tools

• Improvement philosophies and methodologies
• Just-in-time (JIT)
• Thinking Revolution
• Lean Manufacturing
• 20 Keys to workplace improvement
• Measuring and prioritizing the improvements

Material flow and facilities layout

• Signs and reasons for a need to change the layout
• Theoretical Bases
• One-piece flow
• Main types of industrial companies
• Layout types
• Characteristic of the traditional layouts
• Layout design methodology
• Tools for layout study
• Muther's 8 factors

Material flow and design of cellular layouts

• Theoretical basis
• Mass production
• Flow or assembly lines
• Cell layout design justification
• Basic cells design nomenclature
• Cell design methodology
• Cell design tools
• Line Balancing
• Group technology
• Time study
• Leveling production
• Multifunctional workers
• Workforce optimization

Equipment Efficiency: Quality and Poka-Yoke

• Theoretical Bases
• Inspection and SQC (Statistical Quality Control)
• From SQC to Zero defects
• Poka-Yoke design methodology
• Poka-Yoke examples

Equipment Efficiency: Performance and Motion study

• Theoretical Bases
• Motion economy principles
• Motion study tools
• Value analysis
• 5W2H and 5-Why methods
• Worker-machine diagram
• Machine-worker ratio
• Machine-machine diagram

Equipment Efficiency: Availability, performance and maintenance

• Theoretical Bases
• Types of maintenance
• Maintenance program implementation
• Getting started
• Corrective maintenance implementation
• Preventive maintenance implementation
• Autonomous maintenance
• TPM - Total Productive Maintenance
• RCM - Reliability Centered Maintenance
• Maintenance tools
• FMEA for equipment
• Reliability
• P-M Analysis
• Maintenance management

Equipment Efficiency: Availability, quality and SMED

• Theoretical Bases
• Basic steps in a set-up process
• Traditional strategies to improve the set-up process
• SMED methodology
• Preliminary stage
• SMED tools
• First stage tools
• Second stage tools
• Third stage tools
• Zero changeover
• SMED effects and benefits
• Easier set-up process
• On-hand stock production
• Workplace tasks simplification
• Productivity and flexibility
• Economic benefits

Environment Improvements and The 5S

• 5S implementation methodology
• Common steps in the five pillars
• First pillar: Sort
• Second pillar: Set in order
• Third pillar: Shine
• Fourth pillar: Standardize
• Fifth pillar: Sustain
• Implementation of the 5S in offices
• 5S apply to computers
• 5S tools
• Red-tagging strategy
• Sign strategy
• Painting strategy
• Preventive order
• Preventive shine
• Promotion tools
• 5S Benefits and effects

Other improvement keys

• Human resources related keys
• Rationalizing the system
• Improvement team activities
• Empowering workers to make improvements
• Efficient materials use related keys
• Developing your suppliers
• Conserving energy and materials
• Reducing inventory
• Visual control related keys
• Andon
• Kanban
• Technology related keys
• Jidoka
• Using information systems
• Leading technology and site technology

Index

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