Lean RFS (Repetitive Flexible Supply): Putting the Pieces Together

Lean RFS (Repetitive Flexible Supply): Putting the Pieces Together

by Ian Fraser Glenday, Rick Sather

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Product Details

ISBN-13: 9781466578197
Publisher: Taylor & Francis
Publication date: 05/23/2013
Edition description: New Edition
Pages: 168
Product dimensions: 8.50(w) x 10.90(h) x 0.40(d)

About the Author

Ian Glenday started his Lean journey as a microbiologist running a plant producing enzymes from deep-culture fermentation of bacteria. It was here that Ian first began developing RfS concepts and principles for application in process industries.

After taking time out to gain an MBA from Bradford Business School in the UK, Ian joined the manufacturer Reckitt & Colman, where he led an MRPII project To Class A status in the company’s pharmaceutical division. This experience offered Ian a valuable lesson in understanding why applying batch logic in MRP can cause problems.

Ian then moved to Reckitt & Colman’s household and toiletries division, where he initiated and helped implement a pan-European supply chain strategy based on the Lean concept of "every product every cycle," before joining Colman’s of Norwich as head of policy deployment, responsible for applying Lean/RfS thinking across the entire company.

Ian currently divides his time between working with Professor Dan Jones at the Lean Enterprise Academy, UK, where he is a senior fellow, and helping businesses around the world make their own Lean transformations through his company Repetitive flexible Supply Ltd.

Rick Sather is vice president, customer supply chain, for Kimberly-Clark Corporation’s North America Consumer Products Division. In this role, he is responsible for service and efficient product flow from the end of manufacturing through the customer’s retail shelf.

Originally from Wisconsin, Rick received a BS degree in industrial technology from the University of Wisconsin-Stout in 1985, and for the past twenty-seven years has worked in a wide range of supply chain roles. Rick’s Lean journey began in 2005 when he first connected with Ian and began implementing Lean/RfS at Kimberly-Clark. Learning and applying Lean/RfS in direct-line roles has enabled Rick to establish a problem-solving culture focused on delivering exceptional outcomes for people, customers, and shareholders alike.

Table of Contents

Twenty-Five Years at Kimberly-Clark
Does This Sound Familiar?
Do You Face This?
Have You Done This?
Have You Experienced This?
Searching for a Step Change
Summary of Chapter 1

The Fundamentals of Lean/RfS
A Brief History
The Key Components of Lean/RfS
Batch Logic Issue
Alternative Logic of Flow
Lean and Leveled Production
Economies of Repetition
Glenday Sieve
Central Limit Theory and Buffer Tanks
Rockbusting
Summary of Chapter 2

How It Can Be
Some Examples and Anecdotes
Impact on Behavior
Impact on Problem Solving
Impact on Results
Green and Beige People
Policy Deployment
Squash Quosh
Stages in a Lean Transformation
Summary of Chapter 3

The Lean/RfS Corner Pieces
Changing from Batch to Flow
Batch Logic Is Bad
What Is "Responsiveness"?
Calculating the Schedule
Buffer Tank Calculation and Rules
A Lesson in Setting Accurate Buffer Tank Limits
Integrating Lean/RfS into Existing Processes and Systems
Some Results
Summary of Chapter 4

The Lean/RfS Straight Edges
RfS-Dependent Straight Edges
Material—and Other—Flows
Blues and Reds
Lean/RfS Product Costing
Applying RfS Principles Across the Business
Other Straight Edges Supporting Lean/RfS in the Business
Policy or Strategy Deployment?
Strategy Deployment
Key Aspects of Strategy Deployment That Helped Achieve a Transformation in the Way KC Operated
The Difference between Traditional Strategic Planning versus Strategy Deployment
Lean Leadership
Four Rules of Lean
Summary of Chapter 5

The Lean/RfS Center Pieces
Rockbusting
Schedule Breaks
How to Measure Conformance to Plan
Time versus Quantity
Niggles
Summary of Chapter 6

Putting the Pieces Together
Timeline for the Stages in a Lean Transformation
Opportunities for Kimberly-Clark
The 5-Day Rapid Implementation Approach
Stretching Lean/RfS
Forces against Flow
Lean/RfS Fundamental Beliefs
Summary of Chapter 7

Glossary
Recommended Reading
Appendix A
Index

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