Kaizen Assembly

Author: Chris A. Ortiz
Publisher: CRC Press
ISBN: 1420006606
Size: 26.11 MB
Format: PDF, Kindle
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It is easy to learn the philosophy and the concepts of kaizen. It is quite another challenge to translate the philosophy into action. While most books expound on the underlying principles and theory, Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line takes you step-by-step through an actual kaizen event. This approach demonstrates in detail the mindset, the processes, and the practical insight needed to transform your current assembly line into a world-class lean operation. Chris Ortiz brings the experience of over 150 successful kaizen events to the pages of this unique guide. Using clear, succinct, and unambiguous language rather than more general and esoteric terms found in other books, he explains how to implement waste reduction, 5S, time and motion studies, line balancing, quality-at-the-source, visual management, and workstation and assembly line design. Taking a unique approach, the book follows an example of the assembly process for an electric bike including illustrations of nearly every step along the way. Ortiz even includes the most valuable teaching tool of all: past mistakes, how they were overcome, and how to identify and avoid them. Providing expert guidance that will last long after the consultants have left, Kaizen Assembly supplies the tools you need to make kaizen and lean assembly a permanent fixture at the heart of the shop floor.

Kaizen And Kaizen Event Implementation

Author: Chris A. Ortiz
Publisher: Pearson Education
ISBN: 0137022689
Size: 12.41 MB
Format: PDF, Docs
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The Practical, How-to Guide to Succeeding with Kaizen Programs and Events Today manufacturers need kaizen’s continuous productivity improvement and waste reduction techniques more than ever. Kaizen and Kaizen Event Implementation provides specific, detailed solutions that have proven successful in real manufacturing environments. Ortiz, author of the best-selling Lessons from a Lean Consultant, covers every element of a successful kaizen program and offers techniques for implementing several key kaizen events. Drawing on his unsurpassed, in-the-trenches experience, he shares powerful insights into changing cultures, gaining management buy-in, training, reporting, follow-up, and much more. Whether you’re a plant manager, director, engineer, or quality specialist, this book will help you make kaizen work. Avoid common implementation mistakes Find the right champion and establish an effective steering committee Create timelines, select teams and leaders, and define objectives Use kaizen events to implement 5S, standard work, Kanban, and new line designs Includes a chapter-length case study from a real manufacturing firm

America S Assembly Line

Author: David E. Nye
Publisher: MIT Press
ISBN: 0262312921
Size: 62.92 MB
Format: PDF, Mobi
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The mechanized assembly line was invented in 1913 and has been in continuous operation ever since. It is the most familiar form of mass production. Both praised as a boon to workers and condemned for exploiting them, it has been celebrated and satirized. (We can still picture Chaplin's little tramp trying to keep up with a factory conveyor belt.) In America's Assembly Line, David Nye examines the industrial innovation that made the United States productive and wealthy in the twentieth century.The assembly line -- developed at the Ford Motor Company in 1913 for the mass production of Model Ts -- first created and then served an expanding mass market. It also transformed industrial labor. By 1980, Japan had reinvented the assembly line as a system of "lean manufacturing"; American industry reluctantly adopted the new approach. Nye describes this evolution and the new global landscape of increasingly automated factories, with fewer industrial jobs in America and questionable working conditions in developing countries. A century after Ford's pioneering innovation, the assembly line continues to evolve toward more sustainable manufacturing.

Lessons From A Lean Consultant

Author: Chris A. Ortiz
Publisher: Prentice Hall
ISBN: 9780132712842
Size: 79.85 MB
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Making Lean Work: “In-the-Trenches” Help from a World-Class Expert Lean manufacturing can improve productivity and quality, shorten lead times, reduce costs, and improve competitiveness. However, succeeding with lean is not easy. Chris A. Ortiz, one of the country’s most respected lean implementers, shows you exactly how to overcome obstacles, drive value from lean, and sustain success for the long term. Ortiz draws on his experience leading many successful lean transitions and more than 150 kaizen events. He shows you how to prepare for a lean shop floor environment, implement best practice procedures and standards, build executive support, lead kaizen within the factory, and deal with the ups and downs you will inevitably encounter. Forget theory: This is a step-by-step, what-to-do guide for professionals in the trenches—plant and engineering managers, lean managers and directors, Six Sigma practitioners, and working engineers. Topics covered include Seven reasons lean can fail—and how to overcome them Establishing successful kaizen programs: champions, events, teams, goals, tracking, and scheduling Avoiding early stumbling blocks in data collection, waste removal, and process design Getting your operators and supervisors to “buy into” lean Training managers, engineers, and new employees Promoting flexibility and cross-training Using lean to drive growth, not just save money Lean leadership made simple: twelve practical techniques, five simple rules—and ten things not to do Sample audit, tracking, and time study forms

Visual Controls

Author: Chris A. Ortiz
Publisher: CRC Press
ISBN: 1439820929
Size: 19.82 MB
Format: PDF, ePub, Docs
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An effective visual communication system can help manufacturing employees eliminate significant waste from daily tasks. From work-zone color coding to posted metrics, visual controls clarify and simplify the path to enhanced processes and profits. Leaving little to chance, Visual Controls: Applying Visual Management to the Factory provides a detailed explanation of how to apply the Lean principles of 5S to convert your factory to a fully functioning Visual Workplace. It covers the range of methods that collectively compose an effective visual management system and clearly explains management's role in creating a Lean strategy to accomplish the transformation. This book: Considers visual Kanban, material replenishment, and the implementation of a visual maintenance department Details management's role in implementing and sustaining a visual factory Covers the range of visual tools—including tool boards, shadow boards, metrics communication boards, and tool check cards From plant layout and department setup to visual tools and parts, this book facilitates the comprehensive understanding required to initiate positive change through visual communication. The authors supply authoritative insight on how to hasten the required cultural changes, as well as step-by-step instruction for creating visual shadow boards. They also highlight time-tested methods for measuring progress and performance with improved accuracy.

Degarmo S Materials And Processes In Manufacturing

Author: J. T. Black
Publisher: John Wiley & Sons
ISBN: 1118987675
Size: 19.46 MB
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Newly revised for its twelfth edition, DeGarmo's Materials and Processes in Manufacturing, 12th Edition continues to be a market-leading text on manufacturing and manufacturing processes courses for over fifty years. Authors J T. Black and Ron Kohser have continued this book's long and distinguished tradition of exceedingly clear presentation and highly practical approach to materials and processes, presenting mathematical models and analytical equations only when they enhance the basic understanding of the material. Updated to reflect all current practices, standards, and materials, the twelfth edition has new coverage of additive manufacturing, lean engineering, and processes related to ceramics, polymers, and plastics.

The Psychology Of Lean Improvements

Author: Chris A. Ortiz
Publisher: CRC Press
ISBN: 143987879X
Size: 64.91 MB
Format: PDF, ePub
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Fear of change—we all experience it. Some accept change immediately, some gradually adapt, while others may never get there. Whether it’s poor leadership, the inability to change, or pure ego, this Shingo Prize-winning book explores this perplexing commitment to inefficiency. Winner of a 2013 Shingo Prize!/strong The Psychology of Lean Improvements: Why Organizations Must Overcome Resistance and Change the Culture examines the psychology behind why businesses avoid Lean transformations. It investigates why businesses cling to the eight deadly wastes and why they still find ways to place continuous improvement on the back burner. Frequently sought out for his expertise in Lean manufacturing, Chris Ortiz has been featured in a number of trade publications and on the television show Inside Business with Fred Thompson. In this book, Mr. Ortiz breaks down the fear of change within executives and organizational leaders. He examines the psychology of dysfunction, provides insight into why so many businesses fall short in creating visions for growth and prosperity, and identifies tools that can help you address resistance to change. Detailing implementation techniques with a proven track record for success, the book considers specific strategies that can be helpful towards improving your company and changing its culture—including cellular manufacturing, total productive maintenance, setup reduction, Kanban, visual communication, and in-line production. It explains how to get started on your Lean transformation, describes why an economic downturn might be a good time to embrace Lean, and warns of the dangers behind failing to do so. STRONGChris A. Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Watch Chris has being interviewed on Inside Business with Fred Thompson on CNN Headline News. (http://www.youtube.com/watch?v=LMm3fVsbPtM)

Lean Assembly

Author: Michel Baudin
Publisher: Productivity Press
ISBN: 9781563272639
Size: 60.14 MB
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A discussion of Just In Time (JIT) or Kanban manufacturing processes.

Modern Construction

Author: Lincoln H. Forbes
Publisher: CRC Press
ISBN: 9781420063134
Size: 76.31 MB
Format: PDF, Docs
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During the past several decades, the manufacturing and service industries significantly increased their levels of productivity, quality, and profitability through the application of process improvement techniques and information technology. Unfortunately, the construction industry lags far behind in the application of performance improvement and optimization techniques, as well as its overall competitiveness. Written by Lincoln H. Forbes and Syed M. Ahmed, both highly regarded for leadership and innovation, Modern Construction: Lean Project Delivery and Integrated Practices offers cutting-edge lean tools and other productive strategies for the management of people and processes in the construction industry. Drs. Forbes and Ahmed focus mainly on lean construction methodologies, such as The Last Planner(R) System, The Lean Project Delivery System (TM), and Integrated Project Delivery(TM). The tools and strategies offered draw on the success of the world-renowned Toyota Production System (TPS) adapted to the construction environment by construction professionals and researchers involved in developing and advocating lean construction methods. The book also discusses why true lean construction can best occur when all the construction stakeholders, owners, designers, constructors, and material suppliers are committed to the concept of optimizing the flow of activities holistically while de-emphasizing their self-interest. The authors also reintroduce process improvement approaches such as TQM and Six Sigma as a foundation for the adoption of lean methodologies, and demonstrate how these methods can improve projects in a so-called traditional environment. The book integrates these methods with emerging interest in "green construction" and the use of information technology and Building Information Modeling (BIM), while recognizing the human element in relation to motivation, safety, and environmental stresses. Written specifically for professionals in an industry that desperately needs to play catch up, the book delineates cutting-edge approaches with the benefit of successful cases and explains how their deployment can improve construction performance and competitiveness.