Practical Lean Techniques For Building To Demand

Softcover with CD Explains how to develop a wide range of useful skills towards implementing lean, including how to – Map value streams in real-life manufacturing environments Develop future states that can respond to daily changes in customer demand Create flow through the "pacemaker" process when products have different cycle times Set up mixed model heijunka (load leveling) boxes that provide visual schedules at regular intervals Apply mix logic charts to determine finished-goods strategies and meet seasonal demand Creating Mixed Model Value Streams is a hands-on primer for those seeking to implement lean in complex environments. When faced with complex or unique situations, companies often disregard lean principles and fall back on previous practices. In this book, Kevin Duggan describes the lean techniques that can be used when faced with difficult situations such as high product mix, scheduling problems, shared resources, and unstable customer demand. This book will give mangers the knowledge to guide their companies through these tough obstacles and to attain positive bottom line results! The author uses a step-by-step approach, illustrated through a case study based on actual experience, to go beyond the basics of value stream mapping and show how to create future states in the real manufacturing world of multiple products, varying cycle times, and changing demand. The book includes a CD-ROM featuring useful spreadsheets for sorting products into families and calculating equipment needs. Comprehensive and down-to-earth, Creating Mixed Model Value Streams provides the details and new techniques for implementing lean in the complex environment that manufacturers face on their own shop floors. CD-ROM includes: Spreadsheet and tutorial for sorting products into families Spreadsheets for calculating equipment required and for determining the interval for EPEI (Every Part Every Interval) Samples of visual method sheets for standard work Case study value stream maps and mapping icons