Page 337 - How To Implement Lean Manufacturing

Index

A Bravo Line, 221–233
creating flow for, 225–226
ABC Widgets Co., 273–283 economics of, 192–193
cultural change fundamentals at, 281 establishing pull demand systems for, 226
data analysis, 274–280 jidoka for, 226–227
problems with Lean implementation at, 282 lead-time improvements for, 74–75
AIAG (Automotive Industry Action Group), 94 Overall Equipment Effectiveness for, 222
Akao, Yoji, 158 performance improvement results for, 227–232
Alpha Line, 211–220 synchronizing customer supply for, 223
continuous improvement of, 215 synchronizing production for, 223–225
and cultural change fundamentals, 218–219 Buffer stocks, 16, 44, 53–54, 70–71, 112–113, 261
implementing statistical process controls for, calculations, 53-55
215–217 Buffers, 48, 68
initial cultural change efforts, 211–215
leadership at, 211–214, 219
management’s commitment to, 217–218 C
Andons: “Catchball,” 157–158
in Lean manufacturing, 17 Cell(s):
as part of jidoka, 12 advantages of, 195–196
for signaling abnormalities, 106 defined, 69, 195
and transparency, 63, 165, 167–169 flow lines vs., 195–196
Assembly cell, 77 hidden benefits of, 197
Assessment tools, 139–144, 291–298 and reduction of variation, 197
Automotive Industry Action Group (AIAG), 94 Cellular manufacturing, 195–210
Autonomous maintenance, 63 advantages of cells, 195–196
Availability: and cells vs. flow lines, 195–196
defined, 61 and Gamma Line Redesign, 197–209
equipment, 6 Changeovers, 14–15, 37, 68–70, 79, 81, 84–85
line, 18, 143, 147 Chaos, 141
machine, 143 Charities, 34
Available work time, 119
Choice, 90
Churchill, Winston, 165
B CIP (see Continuous Improvement Process)
Balance study, 124–126 Commitment, 139–141, 217, 259
Competition, 33
at Bravo line, 223–225 Constraints, 189–194
at Excalibur manufacturing, 77 addressing, 193
at Gamma line, 201–204 bottlenecks as, 189
at QED motors, 262–263 economics of, 191–193
at Zeta cell, 124–126 moving, 189
Balanced operations, 65 Taiichi Ohno and, 193–194
Baldwin, James, 166 policy, 190–191
Berra, Yogi, 155 Continuity, 21
Bhote, Keki, 95 Continuous improvement:
Bottlenecks: of Alpha Line, 215
as constraints, 189 flowchart, 66
of Gamma Line, 202 in MassProd, 16
in Theory of Constraints, 29 philosophy of, 143
Brainstorming, 95–96, 149–151
in Toyota Production System, 20
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