Whatever your product or process, Productivity Press can fit you with the approach, the tools, and the practical information that will define and strengthen your entire organization's commitment to improvement, from the corner office to the shop floor. We offer the widest selection of award-winning books and informational tools based on the Toyota Production system – adapted, refitted, scaled to meet the needs of any organization.
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Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities.
Equipment Management in the Post-Maintenance Era introduces a new way of thinking to help high-tech organizations manage an increasingly complex equipment base. It also facilitates the fundamental understanding of equipment management those in traditional industries will need to prepare for the emerging microchip era in equipment.
Implementing Standardized Work explains how to measure the performance of operators quickly and simply without sacrificing accuracy. Detailing how to identify the most efficient operators and how to monitor their improvement over time, it describes a method that has been applied with success for years in the automotive industry. Grounded in one of the basic laws of factory physics—mastery of variability—this method can be automated very easily and thereby requires no labor consumption.
This book presents a number of case studies that examine widely held beliefs in the manufacturing industry that have been proven to be groundless. Addressing these beliefs and attitudes that can actually be detrimental to competitiveness, it uses real-world examples to outline simple solutions in each case. Dispelling the myth in question, each chapter supplies specific examples that readers can easily relate to. Among the myths dispelled are that increasing line speed always reduces quality and increases scrap; and that reducing the cost of raw materials will reduce the cost of manufacturing.
Describes how the metrics used by Toyota drive every line item in a financial statement in the right direction. Rather than focus on Lean tools and principles, the new edition of this bestselling reference focuses on what may be the least understood and most critical aspect of a Lean transformation: the building of a Lean culture. In addition to new appendices with background information and insightful stories on Lean leadership and implementation, it includes new information on tactical organization practices, strategy deployment, and Lean culture.
The product wheel (PW) design process has practical methods for finding the optimum sequence, therefore minimizing changeover costs and freeing up useful capacity. It walks the reader through a logical, detailed, step by step, process for designing and implementing the PW technique. Breaking down a fairly complex design process down into discrete, practical, manageable steps, it includes a case study from actual practice that illustrates the design process and the benefits.
This book provides detailed information on how to effectively set-up a manufacturing system and how to accurately measure and control direct labor. It covers several tools that the author developed and implemented in various manufacturing operations, including General Motors, that have proven track records of improving performance significantly.
This second edition takes a step-by-step approach to implementing Lean in complex environments and describes which Lean techniques to use when faced with difficult situations—including high product mix, scheduling problems, shared resources, and unstable customer demand.
This book covers each of the components of lean within the context of the entire lean production system. The author's straightforward common sense approach makes this book an easily accessible on-the-floor resource for every operator.
The new and revised edition of this modern day classic provides the critical piece that will make any lean transformation a dynamic continuous success. It shows you how to implement a transformation that cannot fail by developing a culture that will have all your stakeholders involved in the process and invested in the outcome. It will teach you how to build success from the top down and the bottom up at the same time.
Easy-to-read and apply, each section of the text is loaded with questions, outlines, summaries, diagrams and illustrations. Most importantly, 5S for Operators> provides the foundational knowledge that is essential for implementing not just the 5S System, but overall manufacturing improvements like shorter equipment changeovers, just-in-time inventory, total quality management and total productive maintenance.
Notably flexible and brief, the A3 report has proven to be a key tool In Toyota's successful move toward organizational efficiency, effectiveness, and improvement, especially within its engineering and R&D organizations. The authors provide a number of examples as well as some very practical advice on how to write and review A3 reports