Foreword. Preface. Acknowledgments. How to Use This Book. Focus
Scope.
Organization.
Format.
Structure.
UNIT I. MANUFACTURING INFRASTRUCTURE.
An Overview.
Approach and Scope.
1. Infrastructure Elements.
Summary of Chapter.
Contents.
Relationship of Infrastructure Elements to Other Chapters in the Book.
Competitiveness: Manufacturing Strategy.
Competitiveness: Manufacturing Productivity.
Quality Management: Overview.
Quality Management: ISO 9000.
Employee Involvement and Teams.
Teams: Formation, Development, and Growth.
Benchmarking.
Measurements.
Appendix 1.1: A Case Study of Attitudes Toward TQM (Total Quality Management).
Appendix 1.2: Findings of the U.S. GAO (Government Accounting Office), May 1991.
2. Design for Manufacture.
Summary of Chapter.
Contents.
Relationship of Design for Manufacture to Other Chapters in the Book.
Overview of Design for Manufacture.
New Product and Processes.
Concurrent Engineering.
Best Design Practices: Design for Manufacture and Assembly (DFMA).
Appendix 2.1: Rules for Mechanical Design for Simplicity.
UNIT II. MANUFACTURING PLANNING.
Overview.
3. Manufacturing Information Systems.
Summary of Chapter.
Contents.
Relationship of Manufacturing Information System to Manufacturing Planning.
Overview and Selection of a Manufacturing Information System.
Implementation of a Manufacturing Information System.
Appendix 3.1: Characteristics of an Ideal System.
Appendix 3.2: Example of Special Ability Vendor Comparison
4. Manufacturing System Database.
Summary of Chapter.
Contents.
Relationship of the Manufacturing System Database to Other Major Planning Processes.
The Manufacturing System Database.
Item Master.
Product Structures (Bills of Materials).
Routings.
Work Centers.
Engineering Change Management.
5. Forecasting for Manufacturing.
Summary of Chapter.
Contents.
Relationship of Forecasting to Other Major Manufacturing Planning Processes.
Overview and Management Considerations.
Forecasting Principles.
Forecasting Techniques.
Managing Forecasts in Manufacturing.
Appendix 5.1: Policy for Generating Sales Forecasts and Measuring Forecast Error.
6. Production Planning.
Summary of Chapter.
Contents.
Relationship of Production Planning to Other Major Manufacturing Planning Processes.
Overview and Basic Principles.
Production Planning Format and Technique.
Managing Production Planning.
Appendix 6.1: Sample Production Plan Policy.
7. Master Scheduling.
Summary of Chapter.
Contents.
Relationship of Master Schedule to Other Major Manufacturing Processes.
Overview and Basic Concepts.
Managing Demand.
Rough-Cut Capacity Planning.
Master Schedule: Format and Logic.
Final Assembly Scheduling (Assemble to Order).
Other Uses for Planning Bills.
Managing the Master Schedule.
Appendix 7.1: An Example of an Actual Master Schedule.
Appendix 7.2: Sample: Master Schedule Policy.
8. Materials Requirements Planning.
Summary of Chapter.
Contents.
Relationship of MRP to Other Major Manufacturing Planning Processes.
Overview and Basic Concepts.
MRP Format and Logic.
Determining Lot Size.
Capacity Requirements Planning (CRP).
Managing MRP.
Executing MRP.
Appendix 8.1A: MRP Output: Horizontal Report.
Appendix 8.1B: MRP Output: Vertical Report.
Appendix 8.2: Economic Order Quantity.
UNIT III. MANUFACTURING EXECUTION OVERVIEW.
Overview.
9. Lead-Time Management.
Summary of Chapter.
Contents.
Relationship of Lead-Time Management to Other Chapters in the Book.
Executive Overview of Just-in-Time.
Manufacturing Relationships (Variability, Queues, Capacity, Lead Times, and Throughput).
Shop Layout and Product Flow.
Workplace Organization.
Operations Analysis and Work Methods Design.
MRP II Shop Floor Control.
Uniform Scheduling and Cycle Time.
Applying a Kanban Control System.
Using Different Kanban Systems.
Constraints, Bottlenecks, and Buffer Management.
Lot Sizes and Lead Time.
Transfer Lots and Lead Time.
Setup Reduction.
Hybrid Shop Floor Control Systems.
Statistical Process Control (SPC) and Yield.
Poka-Yoke and Other Forms of Inspection.
Continuous Improvement and Problem Solving.
Standardizing Operations.
Total Productive Maintenance (TPM).
Flexibility.
Reduction of Manufacturing Lead Time: Summary.
Manufacturing Execution Elements and Lead-Time Reduction.
Appendix 9.1: Example of the Use of a Flowchart and a Process Chart.
Appendix 9.2: Operation Charting.
Appendix 9.3: Check List for Fundamental Hand Motions.
Appendix 9.4: Input-Output Control.
Appendix 9.5: Kanban Rules (as Developed by Toyota).
Appendix 9.6: Theory of Constraints.
Appendix 9.7: Determining Control Limits for Attribute and Variable Charts.
Appendix 9.8: Problems with Inspection.
Appendix 9.9: Advantages of Job Rotation (Toyota Production System).
Appendix 9.10: Calculation of Variability.
10. Inventory Management.
Summary of Chapter.
Contents.
Relationship of Inventory Management to Other Chapters in the Book.
Overview and Basic Concepts.
ABC Classification and Application.
Inventory Record Accuracy.
Storeroom Management.
Point-of-Use Storage.
Materials Ordering and Safety Stock.
Customer Service Level Determination and Safety Stock.
Inventory Reduction.
Inventory Costs.
Inventory Performance Measurement.
Inventory Management Program.
Purchasing.
Purchasing Overview.
Make or Buy Decisions.
Supplier Partnerships.
Best Purchasing Practices.
Appendix 10.1: Safety Stock.
Appendix 10.2: Inventory-Reduction Checklist.
UNIT IV. CUSTOMER SERVICE.
Customer Service.
11. Customer Service.
Summary of Chapter.
Contents.
Relationship of Customer Service to Other Chapters in the Book.
Customer Service: Overview.
Customer Service: Basics.
Customer Service Definition and Measurement.
Price Satisfaction.
Management of Customer Service.
Best Practices for Customer-Supplier Relationships.
Customer Best Practices.
Conclusion.Bibliography.Index. 0201633736T04062001
