Creating Mixed Model Value Streams: Practical Lean Techniques for Building to 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 introbul> Features

Table of Contents:
INTRODUCTION Getting Started Challenges of the Real Factory A New Look at 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 Families? Product Families - A Closer Look Developing the Product Family Matrix at EMC Refining Product Families The Current State Map Developing a Future State Question 2: What is the Takt Time at 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: What is 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 Determining the Starting Point The Future State PUTTING IT ALL TOGETHER How Does it All Work? Running the Future State What's Next for the Team? Glossary Important Sources Index

About the Author :
Kevin J. Duggan is a renowned expert with more than 30 years of experience in applying advanced lean techniques to achieve Operational Excellence and the author of three books on the subject: Design for Operational Excellence: A Breakthrough Strategy for Business Growth (McGraw-Hill, 2011), Creating Mixed Model Value Streams: Practical Lean Techniques for Building Demand (Productivity Press, 2002), and The Office That Grows Your Business—Achieving Operational Excellence in Your Business Processes (The Institute for Operational Excellence, 2009). In 1998, he founded Duggan Associates, an international training and advisory firm, to assist companies applying advanced lean techniques into their operations. In 1999, Duggan began working with the Lean Enterprise Institute as a faculty member and also as a Director for the Lean Enterprise Institute Canada while he continued to mentor companies implementing lean. He has developed several advanced workshops such as Creating Mixed Model Value Streams, Creating Flow Through Shared Resources, Creating Flow Through The Supply Chain, Creating Business Process Value Streams, and Lean Product Development that have been adopted by major corporations as part of their production systems. In 2007, he founded the Institute for Operational Excellence, the leading educational center on Operational Excellence, to provide resources including classroom workshops, online training, how-to articles, and books on how to achieve Operational Excellence to a global community of members. Duggan has assisted many major corporations worldwide over the past 12 years, including United Technologies Corporation, Caterpillar, Pratt & Whitney, Singapore Airlines, IDEX Corporation, GKN, FMC Corporation, and Parker Hannifin. A recognized authority on Operational Excellence, Duggan has contributed to publications such as Industry Week, Aviation Week, and American Executive, and has appeared on CNN and the Fox Business Network. Duggan is a frequent keynote speaker, master of ceremonies, and panelist at international conferences such as the Australian Operational Excellence National Forum, the European and American Manufacturing Strategies Summit, European Process Excellence in Manufacturing, and Aviation Week’s Management Forum. He also guest lectures graduate students in business at colleges throughout the United States, including the University of Michigan and Ohio State.