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Production planning, Production management, Management, Production, Computer applications, Selection, Definitions, Manufacturing industries
Production planning, Production management, Management, Systemology, Management techniques, Organization and methods, Information exchange, Data layout
The Creating Level Pull workbook shows you how to advance a lean transformation from a focus on isolated improvements to improving the entire plantwide production system by implementing a lean production control system. "The workbook is unique because it is a step-by-step case study on how to implement a level, pull-based production control system," said author Art Smalley. This is a new step towards 'system kaizen that is not yet well understood outside of Toyota.The lean efforts at most companies focus on "point kaizen" (e.g., reducing set up times, implementing 5S, etc.) that improves a small portion of the value stream running from raw materials to finished products. Or they focus on "flow kaizen" that improves the entire value stream for one product family. Creating Level Pull shows how companies can make the leap to "system kaizen" by introducing a lean production control system that ties together the flows of information and materials supporting every product family in a facility. With this system in place, each production activity requests precisely the materials it needs from the previous activity and demand from the customer is levelled to smooth production activities throughout the plant.[Source : 4e de couv.].
Production planning, Production management, Management, Planning
Identifying and customizing suitable control strategies is a challenging task, especially when production systems have to cope with variable demands, forecast error, and unstable processes. The focus of this book lies on helping companies with complex and discrete production systems to tailor a production control strategy to their needs. Thereby, the mutual merits of “push” and “pull” systems are taken into account, leading to hybrid strategies. Consequently, the book addresses practitioners who are interested in looking behind the scenes and into the physics of production control. A real-life case study demonstrates the practical applicability of the presented framework.
While other books describe production control from an idealistic perspective, this book explains the real process of successful production control. This soup-to- nuts practical guide helps the reader learn: how the scheduling task can be decomposed and organized; how the production control department can be structured; how to hire and train schedulers; and how software tools can be used to augment the scheduler's skill. Author, Kenneth N. McKay is a professor in the Department of Management Sciences, Faculty of Engineering, University of Waterloo. Vincent C. S. Wiers holds a MSc and a PhD in Industrial Engineering and Management Science from the Eindhoven University of Technology.
POLCA (Paired-cell Overlapping Loops of Cards with Authorization) is a card-based visual control system that manages the flow of jobs through the shop floor: at each operation, it controls which job should be worked on next to meet delivery targets. POLCA ensures that upstream operations use their capacity effectively by working on jobs that are needed downstream, while at the same time preventing excessive work-in-process (WIP) build-ups when bottlenecks appear unexpectedly. POLCA is particularly suited to companies manufacturing high-mix, low-volume and customized products. Such companies struggle with long lead times, late deliveries, and daily expediting to meet delivery dates. ERP systems are not designed to deal with this highly variable environment, and add-on software such as Finite Capacity Scheduling systems can require complex installation. Also, the Kanban system does not work well with low-volume or custom production. POLCA has delivered impressive results in such environments. It does not require any complex software implementation: it can be used without an ERP system or it can seamlessly complement an existing ERP system. This book: Provides a step-by-step roadmap on how to implement POLCA; invaluable for both companies that wish to implement POLCA as well as consultants and academics advising such companies. Explains the concepts in practical and easy-to-understand terms by showing detailed shop-floor examples. Includes more than 100 illustrations for understanding how POLCA works as well as for elaborating on details of the implementation steps. Contains case studies written by company owners and executives documenting their POLCA implementation process and the results achieved in various industries in six countries.