Lean Manufacturing: Business Bottom-Line Based (Hardcover)

Introduction: Five Stages of Lean ManufacturingLean ManufacturingIndustrial Dynamics and Bullwhip EffectThree Toolboxes for Lean ManufacturingLet’s Play a “Lean” Game: Manufacturing a GyrocopterFive Stages of Lean Manufacturing: Business Bottom-Line BasedPut Business Bottom Line First: Transfer Function for Production CostProduction Transfer FunctionShort-Term vs. Long-Term Production Transfer FunctionsShort-Term Transfer Function for ProductionTransfer Function for Marginal CostThe Law of Diminishing Returns: Key to Understanding Lean ManufacturingTransfer Function for Average Fixed CostTransfer Function for Average Variable CostTransfer Function for Average Total CostTransfer Function for Long-Term Cost AnalysisGoal Tree and Success Analysis: From Goal Setting to Successful Goal Setting Understanding the Voice of Customers: The Essential ElementsVoice of Customers: Relentlessly Customer FocusedVoice-of-Customers Capability: Critical ElementsVoice of Customers’ Role and ResponsibilitiesAnalyzing Voice of Customers: Law of DemandMaximizing Utility to CustomersKano Model: Integrate the Elements for Voice of CustomersBalance Production and Demand: Value Stream MappingWhat Are Value Streams?What Is Value Stream Mapping?How to Complete Value Stream MappingGuidelines for Developing Value Stream MappingKaizen Event Analysis for Value Stream MappingBusiness Bottom-Line Analysis of Value StreamsFrom Lognormal to Cobb?Douglas Distribution: Lean Production AnalysisTechnology: The Production FunctionLong-Run and Short-Run Production FunctionsThree Stages of ProductionLognormal DistributionCobb?Douglas Production FunctionQuantifying Additional Profit from Productivity GainsTotal Factor ProductivityBusiness Cycles and Demand Fluctuations: Time-Critical Analysis and Decision MakingBusiness Cycles and Demand FluctuationsRegression Analysis: Understanding Customer Demand StatisticallyWhat Is Time Series Analysis?Smoothing TechniquesSummaryHow Demand Fluctuation and “Exogenous Shocks” Influence the Bottom LineHow To Shockproof Your Company: A Lesson from Frank Lloyd WrightBusiness Risk AssessmentRisk Quadrant ChartDevelop a Business Risk Management PlanRisk Assessment MatrixLean Production: Business Bottom-Line BasedApproach for Identifying Productivity ImprovementsQuantifying Additional Profit from Productivity GainsCase Study of a Gyrocopter Manufacturer: Improving ProfitabilityImplement Cellular ManufacturingExample of Cellular Manufacturing: Organize Gyrocopter Production Equipment into Cells to Reduce Inventory and Process TimeExample of Gyrocopter Manufacturing: Eliminate Intermediate Spooling OperationManage Production and Inventory CostsTheory of Constraints: “The Drum Is a Bottleneck"Identifying and Exploring ConstraintsThe Five Focusing Steps and the Continuous Improvement GoalThe General Application of Theory of Constraints to Operations: Drum?Buffer?Rope ApproachPlant Types for OperationsThe Thinking Processes for Implementing Theory of ConstraintsLearning as Actively Addressing ConstraintsLearning to Negotiate the Meaning of ConstraintsAccounting Systems for Lean ManufacturingCase Study: Marion Gyrocopter Corporation (MGC)Conclusion about the Case StudyKanban: Align Manufacturing Flow with Demand PullKanban-Based SystemsWhy Use Kanban?How Kanban WorksThe Rules for KanbanSteps for Implementing KanbanTypes of KanbanKanban DevelopmentKanban Design to Achieve Manufacturing System ObjectivesKanban Card CalculationSummaryJidoka: Implement Lean Manufacturing with AutomationWhat Is Jidoka?Ladder Logic: A Tool to Implement JidokaBoolean Functions for Ladder LogicImplement Jidoka Using Ladder LogicAdditional Functionality for Manufacturing AutonomationPull System, One-Piece Flow, and Single Minute Exchange of Die (SMED)Establish a Pull SystemWhy Use Pull Systems and One-Piece Flow?Overcome Barriers: Two Old BeliefsSingle Minute Exchange of Die (SMED)How to Implement Single Minute Exchange of Die (SMED)Case Study: Flow Management of an Integrated Circuit Packaging Work-in-Process SystemLean Manufacturing Business ScorecardsWhat Are Lean Manufacturing Business Scorecards?How Have Lean Manufacturing Business Scorecards Been Evolved?Lean Manufacturing Business Scorecard for Planning and Policy DeploymentLean Manufacturing Business Scorecards for Problem Solving and Continuous ImprovementBuilding the Business Intelligence StrategyBibliographyIndex