Quick Response Manufacturing : A Companywide Approach to Reducing Lead Times

Publisher's Message xiii(4) Foreword xvii(4) Preface xxi(4) Acknowledgments xxv Part One: A New Way of Thinking Stems from One Principle 1(84) Chapter One: QRM: Not Just Another Buzzword 3(24) How QRM Differs from Other Continuous Improvement and Quality Programs 6(2) Implementing QRM: What Managers Believe 8(3) Perceptions of Implementing QRM in North American Companies 11(6) QRM Principles 17(5) Implementing QRM-The Prerequisites for Success 22(2) Improvement for the Entire Organization Comes from a Single Theme 24(3) Chapter Two: Benefits of QRM 27(26) Benefits of Quick Response in Product Introduction 29(1) Benefits of Quick Response in Existing Production 30(4) Waste Due to Long Lead Times and Late Deliveries 34(4) Results of Quick Response Strategies 38(3) Benefits of Quick Response in Securing Orders 41(3) Benefits of QRM: Forewarned Is Forearmed 44(9) Chapter Three: The Response Time Spiral--Legacy of the Scale and Cost Management Strategies 53(32) The Eras of Scale and Cost Strategies 54(3) The Response Time Spiral for Three Different Manufacturing Environments 57(10) Other Policies That Promote the Response Time Spiral 67(2) Roots of the Response Time Spiral 69(9) Eliminating the Response Time Spiral 78(7) Part Two: Rethinking Production and Materials Management 85(216) Chapter Four: Reorganizing Production 87(20) Seven Key Principles for Restructuring Your Company 88(1) The Manufacturing Cell-Creating the Product-Focused Organization 89(7) Staffing and Training Cell Workers 96(4) Planning, Scheduling, and Control with Cells 100(2) Cells Foster Continuous Improvement 102(5) Chapter Five: Structured Methodology for Implementing Cellular Manufacturing 107(26) Seven Steps to Successfully Implement Cells 108(8) Cellular Manufacturing Implementation Concerns-How to Overcome Them 116(13) Costing and Justification of Cells 129(4) Chapter Six: Creative Rethinking for Cellular Manufacturing 133(20) Challenge Conventional Choices 134(3) Use Technology That Enables a Smaller-Scale Process Implementation 137(3) Change the Sequence of Operations 140(2) Ask, Will the Operation Still Be Required? 142(1) Use Time-Slicing at the Shared Resource 142(2) Implement Time-Sliced Virtual Cells 144(4) Make the Resource Facility Behave Like a Subcontractor 148(1) Split into Two Cells 149(4) Chapter Seven: Capacity and Lot-Sizing Decisions 153(36) Do You Have Good Intuition About Manufacturing System Behavior? 154(2) Factors Influencing Lead Time 156(3) A Basic Formula for Lead Time for the Single Work Center 159(3) Effect of Utilization on Lead Time for the Work Center 162(3) Impact of Lot Sizes 165(6) Impact of Setup Reduction on Lead Time 171(2) Lot Sizing with Multiple Products 173(3) The Hidden Errors in EOQ 176(1) Products Requiring Multiple Operations 177(6) Using Little's Law 183(3) Additional Strategies Based on System Dynamics 186(3) Chapter Eight: Material and Production Planning in the QRM Enterprise 189(34) Rethinking Efficiency 190(7) Pitfalls of On-Time Delivery Measures 197(4) MRP: A Collection of Worst-Case Scenarios 201(9) Align MRP Structure with QRM Strategy 210(10) Using Lead Time Reduction to Continuously Improve Your Processes 220(3) Chapter Nine: POLCA-The New Material Control and Replenishment System for QRM 223(44) Review of Push and Pull Systems 223(4) Key Concepts of JIT (Lean Manufacturing) Compared with QRM 227(6) Misconceptions Regarding the Pull System 233(1) Expanding Beyond JIT Strategies-A Tale of Three Companies 234(5) Summary of Disadvantages of Pull or Flow Methods for QRM 239(4) Material Control-Don't Push or Pull, POLCA 243(20) Three Ds for Success of POLCA: Design, Discipline, and Decentralization 263(4) Chapter Ten: Customer and Supplier Relations 267(34) Supplier Relations-Another Response Time Spiral at Work 268(4) The QRM Approach to Supplier Relations 272(13) Customer Relations-Another Response Time Spiral at Work 285(2) Your QRM Program Can Support Your Marketing Efforts 287(4) Apply QRM Strategies to the Entire Supply Chain 291(10) Part Three: Rethinking Office Operations 301(82) Chapter Eleven: Principles of Quick Response for Office Operations 303(32) Office Operations: A Neglected Opportunity 304(5) The Response Time Spiral for Office Operations 309(5) Organizational Principles Required in the Office 314(21) Chapter Twelve: Tools to Support Q-ROC Implementation 335(28) Information Handling Principles 335(3) Tools to Assist in Q-ROC Implementation 338(11) Concerns with Implementing Office Cells 349(14) Chapter Thirteen: System Dynamics Principles for Quick Response 363(20) Strategically Plan for Idle Capacity 364(2) Replace Traditional Efficiency Measures 366(1) Eliminate Variability 367(2) Use Resource Pooling 369(2) Convert Tasks from Sequential to Parallel 371(1) Reduce Task Setup Times and Minimize Batching 372(1) Use Capacity Management and Input Control 373(1) Create a Flexible Organization 374(9) Part Four: QRM for Rapid New Product Introduction 383(42) Chapter Fourteen: Extending Quick Response to New Product Introduction 385(40) Benefits of Rapid NPI 387(1) Review of NPI Methodologies 388(4) Concurrent Engineering for NPI 392(5) Management Principles for Accelerating NPI 397(5) Design and Manufacturing Principles 402(17) Organizational and System Dynamics Principles Applied to NPI 419(3) Rapid NPI and Your Company's Future 422(3) Part Five: Creating the QRM Enterprise 425(85) Chapter Fifteen: Management Mind-Set to Support QRM 427(18) Capacity and Facilities Decisions 428(5) Quality Strategies 433(2) Organizational Structure and Personnel Decisions 435(1) Production Planning and Scheduling Decisions 436(3) Supplier and Customer Decisions 439(3) Creating the QRM Mind-Set 442(3) Chapter Sixteen: Organizational Structure, Performance Measurement, and Cost Systems 445(52) Drawbacks of Traditional Measures 446(4) New Measure of Performance-Introduction the QRM Number 450(8) Key Issues in Measuring Lead Time 458(11) The Team-Based Organization 469(3) Guidelines for Successful QRM Teams 472(15) Adjusting the Accounting System for QRM 487(6) Epilogue: Democracy in America (Revisited) 493(4) Chapter Seventeen: Steps to Successful Implementation of a QRM Program 497(13) Fifteen Specific Steps to Implementing QRM 498(9) QRM: Management Headache or Opportunity? 507(3) Appendix 510(2) Endnotes 512(22) About the Author 534(2) Index 536