Kanban Made Simple: Demystifying and Applying Toyota's Legendary Manufacturing Process with CD-ROM

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Overview

"Originally developed at Toyota, the approach to manufacturing known as Kanban has helped revolutionize how corporations and suppliers achieve maximum efficiency in getting products to and from the assembly line. When implemented properly, the Kanban technique minimizes waste, avoids overproduction, and ensures quick response to changes and problems.

Kanban Made Simple is the first simple ‘how-to’ guide for incorporating the just-in-time ingenuity of the Kanban system into any manufacturing environment. From the Japanese word for “visual record,” the technique dictates that suppliers deliver parts to the warehouse only as they are needed, reducing storage in the production area. Using ...

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More About This Book

Overview

"Originally developed at Toyota, the approach to manufacturing known as Kanban has helped revolutionize how corporations and suppliers achieve maximum efficiency in getting products to and from the assembly line. When implemented properly, the Kanban technique minimizes waste, avoids overproduction, and ensures quick response to changes and problems.

Kanban Made Simple is the first simple ‘how-to’ guide for incorporating the just-in-time ingenuity of the Kanban system into any manufacturing environment. From the Japanese word for “visual record,” the technique dictates that suppliers deliver parts to the warehouse only as they are needed, reducing storage in the production area. Using before-and-after case studies, this easy-to-follow guide contains information on establishing project goals, forming a Kanban team, and designing the process. Kanban Made Simple helps readers decide if Kanban is right for their organization, then teaches them how to train personnel and administer the program. A ready-to-use CD-ROM, included with the book, guides the Kanban team through the entire implementation process."

Editorial Reviews

Library Journal
Gross (The Fundamentals of Preventative Maintenance) and productivity expert McInnis are both knowledgeable about manufacturing and industrial engineering. Their book, Kanban Made Simple, is not simple at all-at least for anyone without experience in manufacturing. The text is filled with diagrams, flow charts, and tables that illustrate how a "just-in-time" approach to production and distribution reduces waste and potentially increases profits-especially important now because excess inventory has contributed to the economic downturn of recent years, say the authors. They argue that if manufacturers want to apply this theory successfully, they must not fear change and should be willing to decentralize decision making. First developed at Toyota, the concept of "just-in-time" has been in practice worldwide for several years now, but pressure to achieve profitability in tough times is forcing those who have not used it to reconsider how they operate. This book (and its companion CD-ROM) would be a valuable addition to libraries at colleges with industrial engineering or MBA programs, but with so much technical detail it is suited only to large public libraries.-Stephen Turner, Turner & Assocs., San Francisco Copyright 2003 Reed Business Information.

Product Details

  • ISBN-13: 9780814407639
  • Publisher: AMACOM
  • Publication date: 4/15/2003
  • Edition description: Book w/ CD-ROM
  • Edition number: 1
  • Pages: 256
  • Product dimensions: 6.34 (w) x 9.22 (h) x 1.04 (d)

Meet the Author

John M. Gross (Washington, MO) is the author of The Fundamentals of Preventive Maintenance. Kenneth R. McInnis (Washington, MO) has been published internationally on the subject of productivity.

Table of Contents

Preface
Ch. 1 Introduction to Kanban 1
Ch. 2 Forming Your Kanban Team 19
Ch. 3 Conduct Data Collection 32
Ch. 4 Size the Kanban 48
Ch. 5 Developing a Kanban Design 86
Ch. 6 Training 124
Ch. 7 Initial Startup and Common Pitfalls 137
Ch. 8 Auditing the Kanban 148
Ch. 9 Improving the Kanban 158
Ch. 10 Conclusion 178
App. A MRP vs. Kanban 181
App. B Kanban Supermarkets 185
App. C Two-Bin Kanban Systems 189
App. D Organizational Changes Required for Kanban 197
App. E EOQ vs. Kanban 203
App. F Implementation in Large Plants 215
App. G Intra-Cell Kanban 219
App. H Case Study 1: Motor Plant - Casting Kanban 223
App. I Case Study 2: Rubber Extrusion Plant 233
App. J: Acronyms 247
Index 249
About the Authors 259

Customer Reviews

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Sort by: Showing all of 2 Customer Reviews

  • Anonymous

    Posted March 1, 2004

    Highly Recommended!

    Visit any healthy manufacturing operation and you¿ll see a buzz of bewildering activity ¿ parts being moved on overhead cranes, raw materials being wheeled in, line operators checking their production schedules before they change the line over to their next product. Those production schedules, as this book suggests, can really be a hindrance. Operators become dependent on them, although the schedules may not accurately reflect customer demand. The solution? Kanban, which is based on having a communication system right on the factory floor that communicates key indications of customer behavior ¿ buying, ordering, canceling ¿ directly to the workers themselves. Production activity, therefore, is actually scheduled based on customer demand rather than on past expectations, with the advantage that you hold less inventory and operate more effectively. This book (which comes with a compact disc of implementation directions) gives clear insight into this powerful scheduling system employed efficiently by Toyota and other world-class companies. We highly recommend it to executives, managers and supervisors of companies that earn their living by making widgets more successfully.

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  • Anonymous

    Posted September 26, 2011

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