Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand, Second Edition (Paperback, 2)

Introduction
     Questions for Mixed Model
Getting Started 
     Challenges of the Real Factory 
     A New Look at These Challenges with Value Stream Mapping 
     Where Do We Start?
Welcome to EMC Supply Company
     Our Visit to EMC Supply 
     Mixed Model Production

Product Families and the Pacemaker
Question 1?Do We Have the Right Product Families? 
     Product Families: A Closer Look 
     Developing the Product Family Matrix at EMC 
     Refining the Product Families 
     The Current-State Map
     Developing a Future State
Question 2?What Is the Takt Time at the Pacemaker?
     Takt Time
Question 3?Can the Equipment Support the Takt Time? 
     Cycle Time
Question 4?What Is the Interval? 
     Determining the Interval

Flow at the Pacemaker
Question 5?What Are the Operator Balance Charts for the Products? 
     What Time Do We Balance To? 
     Creating Operator Balance Charts 
     Balancing Machine Cycles 
     Identifying the True Pacemaker 
     Material Presentation
Question 6?How Will We Balance Flow for the Mix?
     Balancing Products with High Work Content into the Family
     Varying Labor: A Closer Look 
     Changeovers at the Pacemaker
Question 7?How Will We Create Standard Work for the Mix? 
     Documenting Standard Work 
     Visual Method Sheets 
     Smart Tools and Standard Work

Pitch and Scheduling
Question 8?How Will We Create the Pitch at the Pacemaker? 
     Leveling Using Pitch 
     The Schedule Box 
     Creating Pitch at EMC Supply 
     Inverse Pitch 
     The Future State
Question 9?How Will We Schedule the Mix at the Pacemaker?
     Mix Logic Charts
     Creating the Mix Logic Chart at EMC Supply 
     Leveling the Mix 
     Loading the Schedule Box 
     The Future State

Customer Demand
Question 10?How Will We Deal with Changes in Customer Demand? 
     Smoothing Demand with Dynamic Supermarkets 
     Building to Changing Customer Demand 
     Determining the Starting Point 
     The Future State

How Will Upstream Processes Support the Pacemaker?
Offset Sequencing
Sequenced FIFO

Putting It All Together
How Does It All Work?
     Running the Future State 
     What’s Next for the Team?
Kevin J. Duggan on Lean

Appendices
Lean Glossary
EMC Supply Data Set