Improving Production with Lean Thinking - Javier Santos, Richard A. Wysk, Jose M. Torres
John Wiley, 2014
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Table of Contents
Chapter 1. Continuous improvement tools.
Improvement philosophies and methodologies.
20 Keys to workplace improvement.
Measuring and prioritizing the improvements.
Chapter 2. Material flow and facilities layout.
Signs and reasons for a need to change the layout.
Main types of industrial companies.
Characteristic of the traditional layouts.
Layout design methodology.
Step 1. Formulate the problem.
Step 2. Analysis of the problem.
Step 3. Search for alternatives.
Step 4. Choose the right solution.
Step 5. Specification of the solution.
Step 6. Design cycle.
Tools for layout study.
Muther's 8 factors.
Chapter 3. Material flow and design of cellular layouts.
Flow or assembly lines.
Cell layout design justification.
Basic cells design nomenclature.
Cell design methodology.
Cell design tools.
Chapter 4. Equipment Efficiency: Quality and Poka-Yoke.
Inspection and SQC (Statistical Quality Control).
From SQC to Zero defects.
Poka-Yoke design methodology.
Chapter 5. Equipment Efficiency: Performance and Motion study.
Motion economy principles.
Motion study tools.
5W2H and 5-Why methods.
Chapter 6. Equipment Efficiency: Availability, performance and maintenance.
Types of maintenance.
Maintenance program implementation.
Corrective maintenance implementation.
Preventive maintenance implementation.
TPM - Total Productive Maintenance.
RCM - Reliability Centered Maintenance.
FMEA for equipment.
Chapter 7. Equipment Efficiency: Availability, quality and SMED.
Basic steps in a set-up process.
Traditional strategies to improve the set-up process.
Stage 1. Separating internal and external set-up.
Stage 2. Converting internal set-up to external set-up.
Stage 3. Streamlining all aspects of the set-up process.
First stage tools.
Second stage tools.
Third stage tools.
SMED effects and benefits.
Easier set-up process.
On-hand stock production.
Workplace tasks simplification.
Productivity and flexibility.
Chapter 8. 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 Benefits and effects.
Chapter 9. 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.
Visual control related keys.
Technology related keys.
Using information systems.
Leading technology and site technology.
Appendix A: Numeric problems.
Continuous improvement tools.
JAVIER SANTOS and JOSE M. TORRES are professors in the Department of Engineering at the University of Navarra Technological Campus in San Sebastian, Spain.
RICHARD A. WYSK, PHD is the Leonhard Chair in Engineering, in the Department of Industrial and Manufacturing Engineering at Pennsylvania State University. He is the coauthor of the best selling college textbook Computer-Aided Manufacturing.
To be updated 7 Apr 2016
8 June 2015