Ebook Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand
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Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand
Ebook Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand
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About the Author
Kevin J. Duggan is a renowned expert with more than 30 years of experience in applying advanced lean techniques to achieve Operational Excellence and the author of three books on the subject: Design for Operational Excellence: A Breakthrough Strategy for Business Growth (McGraw-Hill, 2011), Creating Mixed Model Value Streams: Practical Lean Techniques for Building Demand (Productivity Press, 2002), and The Office That Grows Your Business―Achieving Operational Excellence in Your Business Processes (The Institute for Operational Excellence, 2009). In 1998, he founded Duggan Associates, an international training and advisory firm, to assist companies applying advanced lean techniques into their operations. In 1999, Duggan began working with the Lean Enterprise Institute as a faculty member and also as a Director for the Lean Enterprise Institute Canada while he continued to mentor companies implementing lean. He has developed several advanced workshops such as Creating Mixed Model Value Streams, Creating Flow Through Shared Resources, Creating Flow Through The Supply Chain, Creating Business Process Value Streams, and Lean Product Development that have been adopted by major corporations as part of their production systems. In 2007, he founded the Institute for Operational Excellence, the leading educational center on Operational Excellence, to provide resources including classroom workshops, online training, how-to articles, and books on how to achieve Operational Excellence to a global community of members. Duggan has assisted many major corporations worldwide over the past 12 years, including United Technologies Corporation, Caterpillar, Pratt & Whitney, Singapore Airlines, IDEX Corporation, GKN, FMC Corporation, and Parker Hannifin. A recognized authority on Operational Excellence, Duggan has contributed to publications such as Industry Week, Aviation Week, and American Executive, and has appeared on CNN and the Fox Business Network. Duggan is a frequent keynote speaker, master of ceremonies, and panelist at international conferences such as the Australian Operational Excellence National Forum, the European and American Manufacturing Strategies Summit, European Process Excellence in Manufacturing, and Aviation Week’s Management Forum. He also guest lectures graduate students in business at colleges throughout the United States, including the University of Michigan and Ohio State.
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Product details
Paperback: 224 pages
Publisher: Productivity Press; 1st edition (November 7, 2002)
Language: English
ISBN-10: 1563272806
ISBN-13: 978-1563272806
Product Dimensions:
8.5 x 0.5 x 10.8 inches
Shipping Weight: 1.2 pounds
Average Customer Review:
4.6 out of 5 stars
6 customer reviews
Amazon Best Sellers Rank:
#913,307 in Books (See Top 100 in Books)
In this very good book author Kevin Duggan describes an approach to implementing lean manufacturing in challenging environments characterized by a high degree of variety, shared resources, and lumpy demand. All too often in such situations, practitioners conclude that lean principles can be applied incompletely or not at all. Significant missed process improvement opportunities follow from this foundational misunderstanding.Duggan develops his material using as a case study the hypothetical EMC Supply Company. Value stream mapping is used throughout the book to depict the current scenario and the various improvements to achieve the desired future state.The author starts at the very beginning, with a discussion of how the proper definition of product families is critical to the creation of flow in high mix plants. He goes on to introduce the concepts of takt time and the pacemaker operation for the process. From there the discussion moves to the balancing of operations, presentation of materials at the point of use, scheduling the work, and dealing with variation in customer demand.These concepts are applied by the EMC implementation team and are illustrated with an evolving series of value stream maps. As a result the presentation has a "real world" feel to it that should encourage application of the principles.One significant caveat needs however to be mentioned. Successful implementation is about pressing through countless details in every situation. Duggan draws attention to this in various places writing for example, "Material presentation for a high mix of products will take some creativity and planning. This is an area where we will have to sweat the details".In fact, in my experience as a lean implementer, the details need to be sweated at every turn. The concepts may be simple, elegant, and often self evident, but putting them into action requires an almost obsessive attention to a myriad of practical intricacies.For those committed to making this effort the results will be impressive. This book can help make it happen.
If you can get past the first few chapters this book has some useful information. Many Lean books describe the seven (or more) wastes, but this book expands by adding both examples of the waste and the tools used to eliminate that particular type of waste. The book is filled with instructions, examples, forms, and checklists that could easily be adapted to a particular company or department. One checklist that I think will be particularly useful is the Proof of Need Survey. It is a survey that is handed out to employees in an area that will be undergoing improving. The aim of the survey is, through a series of yes/no questions, to gain alignment or "buy-in" to the need for improvement.The book includes a copy of The 5S Desktop (PC) Pocket Handbook - Using the Power of the Toyota Production System (Lean) to Organize and Control Your Electronic Files and Folders.The book attempts to be an all inclusive resource for the Lean Office. I always find this to be a poor approach. I'd rather read several good books on narrow topics than one poor book on a broad topic. The authors actually claim "Though this book is comprehensive and should have everything you require, it should be noted that as authors and continuous improvement specialists, we are not arrogant to think otherwise." The text does often come off as arrogant without much information supporting the author's expertise.
I have to agree with other reviewers. The math is dead simple. And the transition from batch to flow will re-invent your business.Where to book fell down for me was in the examples given. If i worked in a shop which only produced a small list of parts and very little process variation i would be done implementing by now.Where a small business may fall most large facilities/organizations do not. Again, great way to approach changing the way your business runs but without some serious data mining and statistical skills you will end up right where you started.
Great resource.
Most companies have struggled with the application of lean concepts to more complex applications in manufacturing. Most books provide examples for very simple, highly repetitive production. The author Kevin Duggan provides the first real reference of the application of the lean concepts of flow and level pull to mixed model environments. The book details how to identify product families in such situations, with easy to follow guidelines that include consideration of work content, as well as required process steps. There are excellent descriptions of how to adapt the important concept of management timeframe or "pitch" to a mixed model application by taking the traditional "day-by-the-hour" board concept and creating a "floating pitch board".The book is easy to read, making use of a case study and the effective value stream mapping tool to guide the reader throughout. This is a must read for anyone who works in a high mixed model production environment - which is most manufacturers - and not just a "widget" producer.
Great book!!!! Better than expected. If you buy one book on mixed model value streams, buy this book.... Again, super book.
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