Back to Basics: Your Guide to Manufacturing Excellence

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ISBN: 9781574442793 | 1574442791
Cover: Hardcover
Copyright: 3/23/2000

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As organizations move into the future, the operations environment needs to expand into Collaborative Planning and Forecast Replenishment (CPFR), Vendor Managed Inventory (VMI), and an Enterprise Resource Planning (ERP) operating system to become and remain competitive. These innovative and complex methods require an unprecedented degree of accuracy and knowledge of the basics in operations management. Back to Basics: Your Guide to Manufacturing Excellence details the key concepts necessary to expertly apply new approaches such as ERP, CPFR, VMI, and much more.Based on the popular "Back to Basics" columns that appear in the magazine APICS: The Performance Advantage, the structure of the book allows for sufficient development of each topic and is short enough to be quickly read. Topics include: capacity, inventory, inventory accuracy, part numbering, processes, problem solving, and general managerial guidelines. Each chapter has everything you need to understand the issues and their implications.Many careers in operations management begin with production and inventory control. When entering this field, you need to know the basics - in a hurry. Developing excellence takes time and usually comes through the "school of hard knocks". Whether new on the job, or brushing up to implement the latest technology, Back to Basics: Your Guide to Manufacturing Excellence gives you the information you need to become an expert - quickly.

Why the Basics?

(24)

Understanding the Basics

(1)

Oh, No! Not Another Book on Manufacturing!

(5)

How Can Things Be So Wrong, When Everything Seems To Be So Right?

(2)

Why Teach Basics When the Answers Are Out There?

(1)

Basics Are Hard, But Basics Work!

(2)

Mapping Manufacturing Excellence: The Case of the MRPII System That Wasn't

(5)

Overview

(1)

The Case of the MRPII Implementation That Wasn't

(2)

Mapping the Basics of Manufacturing Excellence

(2)

Mapping Manufacturing Excellence: The Four Operations Pillars of Excellence

(1)

Overview

(1)

The Four Operations Pillars of Excellence

(1)

Lead Time: One of the Basic Concepts of Manufacturing

(3)

Overview

(1)

Defining the Concept of Lead Time

(1)

Types of Lead Times

(1)

Major Lessons Learned

(1)

Understanding the Components of Manufacturing Lead Time

(3)

Overview

(1)

Defining the Concept of Manufacturing Lead Times

(1)

Factors Affecting Manufacturing Lead Time

(1)

Importance of Monitoring the Elements of Manufacturing Lead Time

(1)

Major Lessons Learned

(1)

Manufacturing Is Really Just a Balancing Act

(6)

Overview

(1)

The Balance

(3)

Major Lessons Learned

(2)

Understanding Management: The Basics of Problem-Solving

(24)

Why Problem-Solving?

(1)

Understanding the Concept of Manufacturing's Most Fragile Asset: Information

(2)

Overview

(1)

Defining Information

(1)

Critical Traits of Information

(1)

Major Lessons Learned

(1)

Managing Information

(3)

Overview

(1)

Information Management

(2)

The Fragile Nature of Information

(1)

Major Lessons Learned

(1)

When Is a Problem Not a Problem?

(4)

Overview

(1)

Problem vs. Symptom

(1)

Symptoms

(1)

Urgency, Structure, and Orientation of Problems

(1)

Causes

(1)

Major Lessons Learned

(1)

Understanding the Problem-Solving Process

(8)

Size-Up/Description

(2)

Problem-Statement/Diagnostics

(1)

Analysis

(1)

Major Lessons Learned

(1)

Prescription/Alternatives

(1)

Implementation

(2)

General Observations About the Problem-Solving Process

(1)

Responding to a Problem: Solve, Resolve, or Dissolve

(2)

Overview

(1)

Identifying the Three Forms of a Solution

(2)

To Go Forward, Sometimes We Have To Go Backwards

(4)

Overview

(1)

The Importance of Going Back

(2)

How To Go Backwards

(1)

Major Lessons Learned

(2)

What Type of Company Are We?

(8)

Why Should We Care What Type of Company We Are?

(1)

What Type of Company Are We? The Major Dimensions

(4)

Overview

(1)

Manufacturing Settings: Major Dimensions

(1)

Manufacturing Settings Examined

(1)

Job Shop

(1)

Batch

(1)

Repetitive

(1)

Process

(1)

Major Lessons Learned

(1)

What Type of Company Are We? Understanding the Industrial and Manufacturing Contexts

(3)

Overview

(1)

Understanding the Industrial Context

(1)

Understanding the Impact of the Industrial Context

(1)

How Does This Information Help with Software Selection?

(1)

Major Lessons Learned

(1)

Understanding the Importance of Metrics

(12)

Why Metrics?

(1)

The Importance of Metrics (Part 1)

(3)

Overview

(1)

The Total Quality Management Experience at One Company

(1)

What Are Metrics?

(1)

Why Metrics?

(1)

Major Lessons Learned

(1)

The Importance of Metrics (Part 2)

(3)

Overview

(1)

Understanding the Differences Between Metrics

(2)

Major Lessons Learned

(1)

The Importance of Metrics (Part 3)

(5)

Overview

(1)

Metrics and Corporate Strategy

(1)

Gaps as Indicators of Strategic Problems

(1)

Gaps as Indicators of Tactical Problems

(1)

Major Lessons Learned

(2)

Process Thinking: Key to the Basics

(24)

Process Thinking: Understanding the Importance of Processes

(1)

Processes: The Basic Building Blocks of the Operations Management System

(4)

Overview

(1)

What Is a Process?

(1)

Strategic Management Process

(1)

Innovation Process

(1)

Customer Service Process

(1)

Resource Management Process

(1)

Supply-Chain Management Process

(1)

Logistics Management Process

(1)

Performance Measurement

(1)

Other Processes

(1)

Major Lessons Learned

(1)

Identifying the Building Blocks of the Process

(4)

Overview

(1)

Categorization of Activities within the Process

(1)

Operation

(1)

Transportation

(1)

Inspection

(1)

Delay

(1)

Storage

(1)

Major Lessons Learned

(1)

Structure of Processes

(2)

The Ordering of Activities

(1)

Positioning of Activities

(2)

Linking of Activities

(1)

Major Lessons Learned

(1)

Improving Processes: The First Step

(3)

Overview

(1)

Four Types of Processes Found in Every Firm

(1)

The Process as Formally Documented

(1)

The Process as People Think It Exists

(1)

The Process as It Actually Exists

(1)

The Process as It Should Exist

(1)

Major Lessons Learned

(1)

Incorporating Value into Process Analysis

(4)

Overview

(1)

Identify the Critical Customer/Product Traits

(1)

Determine What Constitutes Value for the Critical Customers

(1)

Identify Metrics Consistent with These Specific Traits of Value

(1)

Identify the Critical Processes (Including Bounding and Setting Base Conditions)

(1)

Document (and Validate) the Process as It Currently Exists

(1)

Assess the Performance of the Current System in Light of the Customer-Based Metrics

(1)

Modify the Process Appropriately

(1)

Major Lessons Learned

(1)

Process Analysis: Closing the Value Gap

(3)

Overview

(1)

Disposition Tactics

(1)

Position Tactics

(1)

A Caution Regarding Process Change

(1)

Major Lessons Learned

(1)

Poka-Yoking Our Activities

(3)

Overview

(1)

The Importance of Knowing the Desired Outcomes

(1)

Major Lessons Learned

(1)

Capacity: You Can't Build It if You Don't Have the Capacity

(20)

Capacity: The Resource at the Heart of Manufacturing Excellence

(1)

Capacity: Understanding the Basics

(3)

Major Lessons Learned

(1)

Measuring Capacity

(4)

Safety Capacity

(1)

Making the Transition from Volume to Output

(1)

Major Lessons Learned

(1)

Making the Transition from Capacity in Isolation to Capacity within the Processes

100

(3)

Overview

100

(1)

Capacity in Isolation to Capacity of the System

100

(1)

Measuring Capacity at the Activity

101

(1)

Calculating Capacity of the Overall Process

102

(1)

Major Lessons Learned

102

(1)

Production Scheduling Is No Substitute for Capacity Planning

103

(4)

Overview

103

(1)

Production Scheduling: Defining the Concept

104

(1)

The Problem of Production Scheduling: Solving the Wrong Problems and Hiding Others

105

(1)

Prerequisites for Effective Production Scheduling

106

(1)

Major Lessons Learned

107

(1)

Don't Schedule the Shop; Schedule the Bottleneck

107

(6)

Overview

107

(1)

Bottlenecks: The Key to Simplified, Effective Scheduling

108

(2)

Major Lessons Learned

110

(3)

Understanding the Nature of Setups

113

(8)

Why Be Concerned with Setup?

113

(1)

Understanding the Nature of Setups: The Basics

114

(3)

What Is Setup?

114

(2)

Internal Activity, External Activity, and Capacity Usage

116

(1)

Why Worry About Setups?

116

(1)

General Guidelines for Managing Setups

116

(1)

Understanding the Nature of Setups: Setups and Lot Sizing

117

(4)

Lot Sizing: A Review

117

(1)

Setup Costs

118

(1)

Setup Costs: An Example

118

(2)

Major Lessons Learned

120

(1)

Inventory: The Most Misunderstood Corporate Asset

121

(30)

Inventory Accuracy: What's So Important About the Status of Our Inventory, Anyway?

121

(3)

Overview

121

(1)

Why Inventory Accuracy

121

(1)

The Need for Record Accuracy

122

(1)

Major Lessons Learned

123

(1)

If Inventory Is a Waste, Then Why Study It?

124

(1)

The Fallacy of Inventory Management through FIAT

124

(1)

Understanding the Nature of Inventory: Functions

125

(4)

Overview

125

(1)

What Is Inventory?

125

(1)

Functions of Inventory

126

(1)

Transit

126

(1)

Decoupling

127

(1)

Lot Sizing

127

(1)

Anticipatory

127

(1)

Seasonal

127

(1)

Buffer

128

(1)

Applying the Functions Approach

128

(1)

Major Lessons Learned

128

(1)

Understanding the Nature of Inventory: Forms and Positions

129

(2)

Overview

129

(1)

Forms of Inventory

129

(1)

Position of the Inventory in the Supply Chain

130

(1)

Putting Things Together

130

(1)

Major Lessons Learned

130

(1)

Understanding the Nature of Inventory: ABC Analysis

131

(9)

PART 1

131

(1)

Overview

131

(1)

Develop Categories of Inventories

131

(1)

The Nature of ABC Analysis

132

(1)

ABC and Inventory Control

132

(1)

ABC and Inventory Reduction

133

(1)

Doing ABC Analysis

133

(1)

Major Lessons Learned

134

(1)

Part 2

135

(1)

A Review

135

(1)

Doing ABC Analysis: The Answer

135

(1)

Introducing Costs

136

(1)

Major Lessons Learned

136

(1)

Managing the Slow Movers Using ABC Analysis

137

(1)

Overview

137

(1)

The Problem of the ``Slow Movers''

137

(1)

Managing the Bottom 5%

138

(1)

Strategies for Managing Slow Movers

138

(1)

Major Lessons Learned

139

(1)

From Inventory Accuracy by Accident to Inventory Accuracy by Design: Key Concepts

140

(4)

Overview

140

(2)

Defining Inventory Accuracy

142

(2)

Major Lessons Learned

144

(1)

From Inventory Accuracy by Accident to Inventory Accuracy by Design: Developing the System

144

(7)

Overview

144

(1)

The Structure for Inventory Accuracy

144

(2)

An Effective Cycle-Counting Program: The Key to High Inventory Accuracy

146

(3)

Major Lessons Learned

149

(2)

Odds and Ends of Manufacturing Basics

151

(24)

Manufacturing Excellence Draws on Multiple Sources

151

(1)

Part Numbering: An Introduction

151

(4)

Overview

151

(2)

Defining the Concept of Part Numbering

153

(1)

Assigning Part Numbers: To Be Significant or Not To Be Significant

154

(1)

Major Lessons Learned

155

(1)

Understanding Part Numbering: Significant Numbering (Yes or No)?

155

(3)

Overview

155

(1)

Reasons for Using Significant Part Numbers

155

(3)

Part Numbering: What To Do

158

(2)

Overview

158

(1)

Part Numbering vs. Storage and Retrieval of Information

158

(2)

Comments from Column Readers

160

(1)

Part Numbering: When To Change the Number

160

(3)

How To Handle Prototypes

161

(1)

How To Handle Design Revisions

162

(1)

Part Numbering Revisited

163

(3)

Overview

163

(1)

Another Look at Part Numbering: One Reader's Perspective

163

(2)

Major Lessons Learned

165

(1)

Bills of Materials: An Introduction

166

(2)

The Problem

166

(1)

Defining the Bill of Materials

167

(1)

Bills of Materials: Understanding the Uses

168

(3)

Overview

168

(1)

Uses of the Bill of Materials

168

(1)

Product Definition

168

(1)

Engineering Change Control

169

(1)

Service Part Support

169

(1)

Warranty Analysis/Control

170

(1)

Planning and Scheduling

170

(1)

Costing

171

(1)

Shortage Assessment

171

(1)

Backflushing

171

(1)

Terms and Definitions

171

(1)

Revisiting Bills of Material

172

(2)

Major Lessons Learned

174

(1)

Getting Things Done, and Done Right, the First Time: The Basic of Implementation

175

(20)

Implementing the Savings: The Dumb Way of Achieving Managerial Excellence

175

(4)

Overview

175

(1)

What Are the Savings?

176

(3)

Major Lessons Learned

179

(1)

The Power of WIIFM (What's in It for Me?)

179

(3)

Overview

179

(1)

The Power of WIIFM

180

(1)

Major Lessons Learned

181

(1)

When a Cost Savings Is a Real Cost Savings

182

(3)

Overview

182

(1)

You Don't Understand Costs

182

(1)

True Cost Savings

183

(1)

Opportunity Cost Savings

184

(1)

Incremental Cost Savings

184

(1)

Myopic Cost Savings

184

(1)

Major Lessons Learned

185

(1)

Focus, Urgency, and Time Compression: Understanding the Keys to Success in Implementation

185

(3)

Introduction

185

(1)

The Scenario

186

(1)

The Problem

186

(2)

Hey, Vendor, There's a Paradigm in my Software!

188

(3)

Overview

188

(1)

The Manufacturing Software Decision

188

(2)

So What?

190

(1)

Postscript: Finding a Beginning in the End

191

(4)

Index

195

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Back to Basics: Your Guide to Manufacturing Excellence

Summary

Author Biography

Table of Contents

Supplemental Materials