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Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand | 
 enlarge | Author: Kevin J. Duggan
Publisher: Productivity Press
Category: Book
List Price: $55.00
Buy New: $43.00
You Save: $12.00 (22%)
New (16) Used (9) from $40.00
Avg. Customer Rating:  2 reviews
Sales Rank: 217693
Media: Paperback
Number Of Items: 1
Pages: 198
Shipping Weight (lbs): 1.3
Dimensions (in): 10.8 x 8.4 x 0.7
ISBN: 1563272806
Dewey Decimal Number: 658.5
EAN: 9781563272806
ASIN: 1563272806
Publication Date: November 7, 2002
Availability: Usually ships in 1-2 business days
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Product Description
Apply Lean Thinking to Dynamic, High-Mix Manufacturing
CREATING MIXED MODEL VALUE STREAMS: Practical Lean Techniques for Building to Demand
Kevin J. Duggan How can you apply value stream mapping and lean concepts to the more complex environment created by mixed model (high variety) manufacturing operations? CREATING MIXED MODEL VALUE STREAMS helps to address the challenges of high-mix manufacturing. Topics Covered Include:
Mapping value streams in real-life manufacturing environments
Developing future states that can respond to daily changes in customer demand
Creating flow through the "pacemaker" process when products have different cycle times
Setting up mixed model heijunka (load leveling) boxes that provide visual schedules at regular intervals
Applying mix logic charts to determine finished-goods strategies and meet seasonal demand The author uses a step-by-step approach, illustrated through a case study based actual experience, to go beyond the basics of value stream mapping and to show how to create future states in the real manufacturing world of multiple products, varying cycle times, and changing demand. The book includes a CD-ROM featuring useful spreadsheets for sorting products into families and calculating equipment needs. Comprehensive and down-to-earth, CREATING MIXED MODEL VALUE STREAMS provides the details and techniques for implementing lean in the complex environment that manufacturers face on their own shop floors.
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| Customer Reviews:
Great read, glosses over detail April 10, 2008
2 out of 2 found this review helpful
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.
Accessible Exposition of Principles but the Devil's in the Details September 23, 2006
4 out of 4 found this review helpful
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.
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