Description
Table of ContentsPreface
Acknowledgments
Introduction
1. Eliminating Waste
SCENES IN THE FACTORY
WASTE SIMPLIFY, COMBINE, AND ELIMINATE
2. Back-to-Basics Discipline
HOUSEKEEPING IMPROVEMENTS
WORKPLACE ORGANIZATION
3. Meeting Diversified Customer Needs with Quick Setup
SETUP TIME REDUCTION TECHNIQUES FOR QUICK SETUP
4. Developing Flow on the Production Floor
FROM PROCESS-ORIENTED LAYOUT TO PRODUCT-ORIENTED LAYOUT
MACHINE UTILIZATION VERSUS ON-DEMAND UTILIZATION
5. Expanding Skills for Increased Flexibility
MULTIPROCESS HANDLING
SKILL DEVELOPMENT AND JOB ROTATION
6. Improving Processes for Productivity Gains
PRINCIPLES FOR PROCESS IMPROVEMENT
U-SHAPED LINES
PROCESS ANALYSIS FOR MULTIPLE VARIETIES OF ITEMS
APPROACHES TO PROCESS IMPROVEMENT
7. Strengthening Our Nerves and Muscles
JIDOKA (AUTONOMATION)
LINE STOP CONCEPT
ANDON (TROUBLE LIGHTS)
PRODUCTION CONTROL BOARDS
POKA-YOKE (FOOLPROOF MECHANISMS)
QUALITY AT THE SOURCE
VISUAL CONTROL
8. Aiming for Zero Machine Trouble
PREVENTIVE MAINTENANCE
TOTAL PRODUCTIVE MAINTENANCE
9. Scheduling a Steady Flow for Better Control
LEVELED/MIXED PRODUCTION
CYCLE TIME CONTROL
10. Improving with Standards
STANDARD WORK
WORK COMBINATION CHART
11. Tying Things Together
KANBAN
PRODUCTION CONTROL SYSTEM
12. Redefining the Roles of Conveyors and Transportation
CONVEYORS
TRANSPORTATION
13. Suppliers as Extended Factories
NEW SUPPLIER RELATIONSHIPS
14. Developing Co-Destiny with Employees
JOB SECURITY
IMPROVEMENT THROUGH PEOPLE
15. Eliminating Problems at the Organizational Boundaries
TOTAL OPTIMIZATION AND LOCAL OPTIMIZATION ORGANIZATIONAL STRUCTURE FOLLOWS
ECONOMIC NEED
16. People Make It Happen
CENTRALIZED AND DECENTRALIZED ORGANIZATION
OWNERSHIP, OWNERSHIP, OWNERSHIP
PEOPLE MAKE IT HAPPEN
17. Establishing a Competitive Position
THE FACTORY AS ORCHESTRA
INTEGRATION
GETTING STARTED
GUIDED AUTONOMY
WHAT IS MANUFACTURING STRATEGY?
THE NEW MANUFACTURING CHALLENGE
Epilogue: Vision of the Future
Bibliography
Index
