Dedication | p. xi |
Acknowledgments | p. xiii |
Preface | p. xv |
1 Introduction | p. 1 |
The Scene | p. 1 |
The Response | p. 3 |
The Tools | p. 6 |
Lean Manufacturing | p. 7 |
Cost Cutting-Does it Work? | p. 9 |
Why Do Executives Persist in Cost Cutting? | p. 11 |
Kaizen | p. 12 |
Total Productive Maintenance | p. 13 |
Six Sigma | p. 13 |
Supply Chain Management | p. 14 |
Reliability-Centered Maintenance | p. 14 |
Predictive Maintenance | p. 15 |
Root Cause Analysis | p. 16 |
Other Tools | p. 17 |
Summary | p. 18 |
References | p. 19 |
2 Aligning the Organization | p. 21 |
Why We Must Align the Organization | p. 21 |
Aligning for Manufacturing Excellence | p. 24 |
Developing and Using an Asset Management Strategy as an Alignment Tool | p. 30 |
CEO Compensation: Mis-Aligning the Organization | p. 35 |
Internal Equtability | p. 38 |
CEO Compensation and Internal Equity | p. 39 |
External Competitiveness | p. 42 |
CEO Compensation and External Competitiveness | p. 43 |
Initiative Overload: A Mis-Alignment Issue | p. 46 |
Summary | p. 47 |
References | p. 49 |
3 Innovation | p. 51 |
Introduction | p. 51 |
Cost Cutting vs. Creating an Innovative Environment | p. 54 |
Getting Lower Costs Through "Little Innovation" | p. 55 |
Creating Expectations | p. 56 |
Outsourcing/Offshoring: The Loss of Innovation | p. 59 |
Two Scenarios | p. 61 |
Human Capital: The Heart of Innovation and Value Creation | p. 64 |
Other Human Asset Valuation Methods | p. 70 |
Summary | p. 73 |
References | p. 75 |
4 Leadership and Teams | p. 77 |
Introduction | p. 77 |
Leaders vs. Managers | p. 77 |
Vision, Reality, Courage, and Ethics | p. 79 |
Personal Humility and Professional Resolve | p. 79 |
Building Character Through Principles | p. 80 |
Leadership: Aligning the Organization | p. 81 |
Five Practices of Exemplary Leadership | p. 82 |
The 21 Irrefutable Laws of Leadership | p. 82 |
Inspiring Ordinary People to Extraordinary Performance | p. 82 |
Summary: Common Traits of Leadership | p. 84 |
Teams and Teamwork | p. 85 |
Self-Managed Teams: Caution | p. 89 |
Organizational Context | p. 91 |
Expert Team Coaching | p. 92 |
Team Leader Execution Skills | p. 93 |
Corporate Level Observations | p. 94 |
The Dysfunctions of Teams | p. 94 |
Summary | p. 95 |
References | p. 95 |
5 Managing Change | p. 97 |
Introduction | p. 97 |
Articulate a Compelling Reason for Change | p. 99 |
Apply Leadership and Management Principles | p. 100 |
Communicate the Strategy and Goals | p. 101 |
Facilitate Employee Implementation of the Change Process | p. 102 |
Measure the Results: Reward Good Behavior, Challenge Bad Behavior | p. 103 |
Stabilize the Organization in the New Order | p. 105 |
Succession Planning and Management | p. 106 |
Beta's Omega Division | p. 106 |
Better Succession Management | p. 108 |
Selecting the Right Managers | p. 109 |
Sustaining Improvement | p. 110 |
Summary | p. 112 |
References | p. 112 |
6 Business Level Failure Models and Effects Analysis: Selecting the Right Improvement Projects and Tools | p. 115 |
The Manufacturing Plant as a Business System | p. 116 |
Business-Level Failure Modes and Effects Analysis (FMEA) | p. 117 |
Typical Results | p. 121 |
Selecting the Right Tools | p. 121 |
Beta's Allen Central Plant | p. 123 |
Beta's Swampton Plant | p. 124 |
Beta's Martin Plant | p. 125 |
Beta's Leets Plant | p. 128 |
Beta's Van Lear Plant | p. 129 |
Beta's Blany Plant | p. 129 |
Beta's Ivel Plant | p. 130 |
Summary | p. 131 |
Reference | p. 133 |
7 Lean Manufacturing | p. 135 |
Lean Manufacturing: A Very Brief History | p. 135 |
Lean Characteristics | p. 137 |
The Toyota Way | p. 141 |
Philosophy: Long-Term Thinking | p. 141 |
Processes: Eliminate Waste | p. 143 |
People and Partners: Respect, Challenge, and Grow Them | p. 145 |
Problem Solving: Continuous Improvement and Learning | p. 146 |
Keeping Things Simple | p. 148 |
Toyota Production System Summary | p. 150 |
Decoding the DNA of the Toyota Production System | p. 152 |
Beta's Banner Division | p. 153 |
Banner Division's Boldman Plant | p. 154 |
Banner Division's Blue River Plant | p. 154 |
Summary | p. 156 |
References | p. 157 |
8 Kaizen | p. 159 |
Introduction | p. 159 |
Ideas Are Free | p. 160 |
Major Principles of Kaizen | p. 164 |
Kaizen and Management | p. 164 |
5S | p. 166 |
Standardization | p. 166 |
Elimination of Muda (Waste) | p. 167 |
Kanban | p. 168 |
Beta's Dorton Plant | p. 169 |
Beta's Burton Plant | p. 171 |
Summary | p. 172 |
References | p. 172 |
9 Total Productive Maintenance | p. 173 |
Fundamentals of TPM | p. 174 |
OEE | p. 176 |
OEE/TPM and Safety Performance | p. 180 |
Operator Care | p. 182 |
Operator/Owner Guidelines | p. 183 |
Maintainer/Improver Guidelines | p. 183 |
Quick Changeover | p. 185 |
Relationship Between TPM and RCM | p. 186 |
Beta's Ivyton Plant | p. 186 |
Beta's Grethel Plant | p. 188 |
Summary | p. 189 |
References | p. 191 |
10 Six Sigma | p. 193 |
Definition of Six Sigma | p. 193 |
The Methodology | p. 195 |
An Alternative Application of Six Sigma Principles | p. 197 |
Beta's Waldo Plant | p. 198 |
Beta's Staffordville Plant | p. 199 |
Beta's Teaberry Plant | p. 199 |
Six Sigma and Lean Manufacturing | p. 200 |
Summary | p. 201 |
References | p. 203 |
11 Supply Chain Management | p. 205 |
Supply Chain Management: One Model | p. 205 |
Supply Chain Management: Another Model | p. 208 |
Differentiating and Managing Customers | p. 208 |
Cost of Service | p. 212 |
Good Suppliers | p. 212 |
Policy Deployment | p. 213 |
Functional Organizations vs. Supply Chain Organizations | p. 214 |
Beta's Falcon Plant | p. 215 |
Beta's Tomahawk Division | p. 216 |
Beta's Topmost-DPD Division | p. 217 |
Beta's Melvin Plant | p. 218 |
Beta's Weeksbury Division | p. 219 |
Summary | p. 219 |
References | p. 220 |
12 Reliability-Centered Maintenance | p. 221 |
Introduction | p. 221 |
RCM Standard SAE JA1011 | p. 223 |
An RCM Example | p. 225 |
Criticality Analysis | p. 227 |
RCM and Developing a Maintenance Strategy | p. 228 |
Potential RCM Pitfalls and Suggestions | p. 233 |
PM Optimization: RCM in Reverse | p. 235 |
Beta's Lowhansville Plant | p. 238 |
Beta's Carr Creek Plant | p. 239 |
Beta's Oil Springs Plant | p. 240 |
RCM and TPM: The Relationship | p. 241 |
RCM and Six Sigma: Common and Uncommon Characteristics | p. 243 |
Summary | p. 243 |
References | p. 244 |
13 Predictive Maintenance/Condition Monitoring | p. 247 |
Introduction | p. 247 |
Cost Reduction Benefit of CM | p. 247 |
Preventive Maintenance (PM) and Increased Costs | p. 250 |
Common Mistakes in CM Programs | p. 251 |
CM: Understanding and Managing the Degradation Process | p. 252 |
PdM/CM Technologies | p. 255 |
Vibration Analysis | p. 256 |
The Basics of Vibration Analysis | p. 258 |
Lubrication/Fluid Analysis | p. 261 |
Infrared Thermography | p. 265 |
Motor and Electrical Testing | p. 271 |
Specific Motor Current Testing | p. 272 |
Airborne Ultrasonic Testing | p. 273 |
Operator Process Condition Monitoring | p. 275 |
Contracting CM | p. 277 |
Beta's Boons Camp Plant | p. 279 |
Beta's Stanville Plant | p. 280 |
Beta's Dwale Plant | p. 281 |
Beta's Watergap Plant | p. 282 |
Summary | p. 282 |
References | p. 284 |
14 Root Cause Analysis | p. 285 |
Introduction | p. 285 |
Three Common Approaches | p. 287 |
5 Whys | p. 287 |
CEDAC | p. 290 |
Apollo RCA Methodology | p. 294 |
RCA Example | p. 296 |
Results | p. 297 |
RCA Rt | p. 298 |
The Development of a Cohesive Approach | p. 298 |
The Importance of Problem Definition and Follow Through | p. 301 |
Cause Trees | p. 302 |
Action Management | p. 303 |
Incidents and Ongoing Concerns | p. 304 |
Summary | p. 304 |
References | p. 305 |
15 Closing | p. 307 |
Beta's Strategy | p. 307 |
Nominal Hierarchy for Application of the Strategy and Tools | p. 310 |
Reference | p. 313 |
Appendix A Planning and Scheduling | p. 315 |
References | p. 322 |
Appendix B Performance Measurement | p. 323 |
Return on Net Assets (RoNA) or Return on Replacement Value (RoRv) | p. 329 |
Measure for Weakness | p. 329 |
Beta's Instrument Division | p. 330 |
Closing | p. 333 |
References | p. 334 |
Appendix C Listing of Commonly Used Improvement Tools and Terms | p. 335 |
Reference | p. 358 |
Index | p. 359 |