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Fast Track to Waste-Free Manufacturing: Straight Talk from a Plant Manager / Edition 1

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Overview

Manufacturing in the United States is currently undergoing a major transition, yet large numbers of manufacturers simply do not recognize what it is all about. Many still operate under out dated manufacturing practices and do not see that the enemy is not the competition, but rather their own system of production. Batch, or mass manufacturing is still the preferred system of production for most U.S.-based industry. But to survive, let alone become globally competitive, companies will have to put aside their old mass manufacturing paradigms and completely change their entire production system.

WFM will give you step-by-step directions to making rapid, lasting changes. Davis has created 4 new drivers of WFM and has linked them so you know what order to do them in and when it is time to move to the next driver. He covers nearly every aspect of the lean revolution and provides essential tools and techniques you will need to implement WFM. He also addresses the critical management issues that will arise in any plant that is striving to be world class.

Drawing from more than 30 years of manufacturing experience, John Davis gives you tools and techniques for eliminating anything that cannot be clearly established as value added. WFM is not a theory. It is a proven process, and one the author has successfully implemented. He shares with you from his own experiences in guiding manufacturers through this process. Davis fully details the journey of a factory that moved from mass to waste-free manufacturing in a matter of 24 months. This factory was nationally recognized by wall street analysts as an effective manufacturing model. You get to sit in on their meetings and learn from their triumphs and failures.

So hold on to your hat, because you are about to learn how to do what most in the field of world class manufacturing tell you isn't possible: to rapidly deploy WFM and change the system of production. Filled with checklists, an ongoing case study and, most important, strategies that will work, Fast Track to Waste-Free Manufacturing: Straight Talk from a Plant Manager will provide you with the principles and methodology for WFM and a road map for its implementation. All you need is the will, the focus, and a sense of urgency about the future of U.S. manufacturing. If you are a plant manager, foreman, supervisor, or executive who wants to quickly transform your factory into a world class manufacturer, Mr. Davis' WFM methodology is "must reading."

A 296 minute abridged version of this book is also available on four compact discs or audio cassettes from Productivity Press.

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Editorial Reviews

Booknews
Drawing on a lifetime of experience in manufacturing, industrial engineering, management, and consulting, Davis details a new and proven system for making rapid changes and joining the "lean revolution." He provides essential tools and techniques needed to implement waste-free manufacturing, and addresses critical management issues that will arise in any plant. He shares his own experiences in guiding manufacturers through this process, and details the journey of a factory that moved from mass to waste-free manufacturing in 24 months. Davis is retired from the position of director of operations at two manufacturing facilities. Annotation c. Book News, Inc., Portland, OR (booknews.com)
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Product Details

  • ISBN-13: 9781563272127
  • Publisher: Taylor & Francis
  • Publication date: 3/28/1999
  • Series: Shopfloor Series
  • Edition description: New Edition
  • Edition number: 1
  • Pages: 304
  • Product dimensions: 6.00 (w) x 9.00 (h) x 0.90 (d)

Table of Contents

  1. Introduction: The Revolution Has Just Begun
  2. Confronting the Deep Dark Dungeon
  3. The Plant Manager's Manifesto
  4. The New Competition and the Old Barriers
  5. Waste-Free Manufacturing—changing the rules
  6. Examining the WFM Drivers
  7. Beginning the WFM Journey
  8. Changing the Culture
  9. Measuring Progress—what to measure and how
  10. Organizational and Operational Issues to Support WFM
  11. Staying the Course on Your Never-Ending Journey
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Introduction

Why this book was written

After almost 30 years in manufacturing, which included time in the plant management ranks, I was provided the opportunity to lead a team of professionals who were assigned the task of helping operations implement the principles, concepts and techniques of "lean manufacturing". This team literally traveled the globe for a period of four years and worked with plants who were vastly diversified in the products and services they provided. It was in this role where it became apparent to me that the problems most organizations suffer in making the substantial change, associated with moving from a "batch" manufacturing environment to "lean" manufacturing principles, rests not with any lack of will but in knowing precisely what to do and when to do it. Further, little if any material existed regarding such subjects as how to work with the union, how to best utilize "displaced employees", how to seriously and effectively measure the change process and, most important, how to know when you have indeed made significant steps in this never ending journey. I therefore felt compelled to document my thoughts and experiences on the subject and as a result, with the superb help and support of Productivity Press, Fast Track To Waste Free Manufacturing became a reality. It is my sincere hope that this work will serve to help those charged with the enormous task of effectively shifting their manufacturing operations to a globally competitive status.

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