About the Book
Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While, a number of innovators have successfully applied Lean principles to these industries over the last two decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others.
Drawing on 40 years of application experience at one of the world’s largest chemical and materials manufacturers, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing,
Lean for the Process Industries: Dealing with Complexity –
Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations
Explains how to adapt value stream mapping for process operations
Shows how to identify the root causes of bottlenecks, and systemically eliminate them
Provides process-oriented modifications that will enhance the usefulness of Cellular Manufacturing, Heijunka Production Leveling, and Pull Replenishment Systems
Discusses the role of process operations management in a Lean strategy
Whether you are manufacturing consumer products such as foods, paints, and pharmaceuticals, or materials such as bulk chemicals, sheet goods, and synthetic fibers, this book shows you how to achieve that enviable level of performance where continual improvement becomes inherent to your processes.
Table of Contents:
Introduction:
Lean Overview
The Process Industries: what makes them unique
Value Stream Mapping the Process Industries
The Basics:
Kaizen Events
The 8 Wastes in the Process Industries
Set-up reduction & SMED
Total Productive Maintenance
Visual Management
Dealing with Complexity:
Finding, managing, and improving Bottlenecks
Cell design in the Process Industries
Production scheduling, production sequencing, production leveling: Product Wheels
Lead time improvement
Postponement: Finish-to-Order
Pull Systems
Supermarket design
Fixed interval replenishment
Fixed quantity replenishment
Managing variability: Safety Stock
Creating the Future State Map
The importance of robust business processes
Appendix: The Hypothetical Process description and data
About the Author :
Lean Dynamics LLC, Newark, Delaware, USA
Review :
...provides a nice balance between lean philosophies and concepts, as well as guidance and examples. The content enables operations managers to gain an understanding of basic ideas and principles, and it is detailed enough that process engineers and lean practitioners can learn specific applications of the various tools. If you work in the process industry and want to make improvements to your lean manufacturing operations, Lean for the Process Industries is highly recommended. -Janice M. Gullo, CFPIM, CSC writing in APICS magazine, July/August 2010 King has done a masterful job of describing the application of lean concepts and tools, which originated in discrete part and assembly operations, to the process industries. His book will become the handbook for lean practitioners in those industries. -Ted Brown, Lean Competency Champion, DuPont Operations & Supply Chain Center of Competency King truly understands Lean Manufacturing and the intricacies of applying Lean tools in the process industries; he has mastered the theory and the application of Lean. - Douglas R. Kroeger, past president, IIE Process Industries Division; manufacturing manager, Nestle Nutrition This book is a must-read for Lean practitioners in chemicals, pharmaceuticals, and other process industries. - Tom Knight, founder and chief strategy officer, Invistics Corporation King does a wonderful job blending the complementary aspects of Lean and the theory of constraints in an integrated approach specific to a continuous process flow environment. - Jeff Oelke, program director, Operations Management Certificate, University of Wisconsin-Madison
…provides a nice balance between lean philosophies and concepts, as well as guidance and examples. The content enables operations managers to gain an understanding of basic ideas and principles, and it is detailed enough that process engineers and lean practitioners can learn specific applications of the various tools. If you work in the process industry and want to make improvements to your lean manufacturing operations, Lean for the Process Industries is highly recommended.
—Janice M. Gullo, CFPIM, CSC writing in APICS magazine, July/August 2010
King has done a masterful job of describing the application of lean concepts and tools, which originated in discrete part and assembly operations, to the process industries. His book will become the handbook for lean practitioners in those industries.
—Ted Brown, Lean Competency Champion, DuPont Operations & Supply Chain Center of Competency
King truly understands Lean Manufacturing and the intricacies of applying Lean tools in the process industries; he has mastered the theory and the application of Lean.
— Douglas R. Kroeger, past president, IIE Process Industries Division; manufacturing manager, Nestlé Nutrition
This book is a must-read for Lean practitioners in chemicals, pharmaceuticals, and other process industries.
— Tom Knight, founder and chief strategy officer, Invistics Corporation
King does a wonderful job blending the complementary aspects of Lean and the theory of constraints in an integrated approach specific to a continuous process flow environment.
— Jeff Oelke, program director, Operations Management Certificate, University of Wisconsin-Madison
