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Progressive Manufacturing

Progressive Manufacturing

Managing Uncertainty While Blazing a Trail to Success
By Soli J. Engineer
Hardcover, 6x9, 272 pages
ISBN: 1-932159-29-0
February 2005
APICS

Availability: In stock

Retail Price: $49.95
Direct Price: $44.95

Read the Reviews
“Unlike other books on industrial planning and control, this one contains a wealth of information on the people factor — the most important of the three elements required for success in any commercial business. This book will be useful to people at all levels of the organization in manufacturing and distribution businesses.”

- From the foreword by industry pioneer George W. Plossl
About the Item
Manufacturers are continuously searching for solutions to their seemingly never-ending inventory, delivery, cost, productivity, quality, and profit woes. Progressive Manufacturing: Managing Uncertainty While Blazing a Trail to Success provides powerful, cutting-edge, common-sense solutions to these and other perennial problems faced by most organizations. The book delineates the three keystones essential to achieving any significant degree of success — people, products or services, and processes. It presents thought-provoking ideas and methods for simplifying processes at every level.

Author Soli Engineer explores topics that are instrumental to achieving success, but are often avoided, such as work breakdown structure and improvement curve theory, and explains “how to” and “how not to” approaches to production and inventory management. This book provides innovative techniques that take you beyond the tried and true to achieve real operational success and increased profits. It is a must-read for operations, production, and supply chain professionals.
Key Features
  • Challenges unfounded comparisons between MRP (a procedure) and JIT, Kanban, and TQM (philosophies)
  • Clarifies a key interface between engineering and manufacturing — the Product Data Management (PDM) system
  • Provides innovative methods for using bills of material to improve productivity and multiple ways to reduce lead times and inventory
  • Emphasizes the vital ingredients for achieving success and the dangers of ignoring one or more of them
  • WAV offers free downloadable cost roll-up exercises, learning and improvement curve tools, and PowerPoint slides describing how to effectively establish and achieve improvement objectives — available from the Web Added Value™ Download Resource Center at www.jrosspub.com/wav
  • About the Author(s)
    Soli J. Engineer is a management consultant and the sole proprietor of SJE Consultants & Associates. He offers more than 25 years of management, global business, and manufacturing experience and is a member of the American Production & Inventory Control Society (APICS) and Certified in Production and Inventory Management (CPIM). He has taught several certification courses and is a sought-after speaker and published author.
    Table of Contents
    Section I: People

    Chapter 1: Change — The Biggest Hurdle!
    A Professional Rut
    For Whom Do You Work?
    Types of Changes
    Leadership and Teamwork
    Cause for Concern
    What Does It Take to Effect Change?
    Management’s and Employees’ Responsibility

    Chapter 2: Organization
    Keep It Shallow
    Mission
    Credo of the Organization
    Right People in the Right Jobs
    Motivation
    Incentives and Intra-Company Competition
    Performance Evaluations
    Fear
    The Real Objective

    Chapter 3: My Five C’s
    Care
    Comprehension
    Commitment
    Communication
    Common Sense

    Section II: Products and Services

    Chapter 4: Product Design
    Bills of Material
    Work Breakdown Structure
    Streamlining the Procurement Effort
    Can Bills of Material Help with Outsourcing the Finished Product?
    Establishing a “Statement of Work” for Each Supplier
    Managing “Free-Issued” Components to Suppliers
    Changes and Corrections to Bills of Material

    Chapter 5: Inventory
    How Much Is Enough?
    Types of Inventory
    Why Carry Inventory?
    Daily Cycle Counts

    Chapter 6: Lead Times
    Components of Lead Time
    Purchasing, Manufacturing, and Administrative Lead Time
    Pull and Issue Components from Stock
    Purchase Requisition Approval
    Stocking Parts and Finished Goods
    Minimizing Administrative Lead Times
    Minimizing Traditionally Accepted Components of Lead Times
    Setup, Wait, and Move Time

    Chapter 7: Product Cost
    Costing Methods
    Cost Elements
    Purchased and Manufactured Components
    Product Pricing
    Improvement Curve Theory
    Continuity
    Role of Improvement Curves in Pricing
    Supply Chain Management

    Section III: Processes

    Chapter 8: Quality
    ISO Certification
    Continuous Improvement: Processes
    Understanding and Managing Process Variations
    Process Evolution — Thanks to Technology

    Chapter 9: Engineering Processes
    Design Systems
    Product Data Management Systems
          Repository for Engineering Information
          Data Library
          Engineering Change Management
          Buffer Between Engineering and Manufacturing Data
          Examples
    System Compatibility and Interfaces
    Data Transfers Between PDM and Business Systems
    Establishing a Workflow: The Manual System

    Chapter 10: Manufacturing Processes
    Planning Processes
          Business Planning
          Sales and Production Planning
          Master Schedule
          Capacity Requirements and Shop Floor Scheduling
          Material Requirements
    Execution Processes
          Issuing Work Orders
          Issuing Purchase Orders
          Inventory Management
          Other Processes
    Reporting Processes

    Chapter 11: Manufacturing Philosophies
    A Bit of History
    The Basic Requirements
    “Push” Versus “Pull” Systems
    Work Order or Kanban?
    Have We Come Full Circle?
    Effect on Our Industry
    What Really Makes JIT, Kanban, and TQM Different?

    Section IV: The Future

    Chapter 12: Where Do We Go from Here?
    The Traditional Tool Kit
    One Size Does Not Fit All
    Cherry-Picking Is Not a Good Idea
    One of My Experiences

    Appendix A
    Cost Roll-up (Example)
    Improvement Curves
    Computing the Slope

    Appendix B
    The Logic of MRP
    Inputs to MRP
    Output of MRP
    The MRP Process
    Generating a Material Requirement Plan

    Bibliography

    Index
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