Lean manufacturing

Manufacturing
Tools, Techniques, and How To Use Them

Lean

The St. Lucie Press/APICS Series on Resource Management

Titles in the Series
Applying Manufacturing Execution Systems
by Michael McClellan

Back to Basics: Your Guide to Manufacturing Excellence
By Steven A. Melnyk R.T. “Chris” Christensen

Enterprise Resources Planning and Beyond: Integrating Your Entire Organizationby Gary A. Langenwalter

ERP: Tools, Techniques, and Applications for Integrating the Supply Chain
by Carol A. Ptak with Eli Schragenheim

Integral Logistics Management: Planning and Control of Comprehensive Business Processes
by Paul Schönsleben

Inventory Classification Innovation: Paving the Way for Electronic Commerce and Vendor Managed Inventory
by Russell G. Broeckelmann

LeanManufacturing: Tools, Techniques, and How To Use Them
by William M. Feld

Macrologistics Management: A Catalyst for Organizational Change
by Martin Stein and Frank Voehl

Restructuring the Manufacturing Process: Applying the Matrix Method
by Gideon Halevi

Supply Chain Management: The Basics and Beyond
by William C. Copacino

Manufacturing
Tools, Techniques, and How To Use Them
byLean

WILLIAM M. FELD

The St. Lucie Press/APICS Series on Resource Management

St. Lucie Press
Boca Raton • London New York • Washington, D.C. Alexandria, Virginia

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__________ Feld, William M. Lean manufacturing : tools, techniques, and how to use them / by William M. Feld. p. cm. Includes bibliographical references (p. ) andindex. ISBN 1-57444-297-X (alk. paper) 1. Production management. 2. Costs, industrial. 3. Production management — Case studies. I. Title. TS155 .F4985 2000 658.5—dc21 00-059163

Library of Congress Cataloging-in-Publication Data

This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A widevariety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming,and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. The consent of St. Lucie Press does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from St. Lucie Press for such copying. Direct all inquiries to St. Lucie Press, 2000 N.W.Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe.

© 2001 by William M. Feld No claim to original U.S. Government works International Standard Book Number 1-57444-297-X Library of Congress Card Number 00-059163 Printed in the UnitedStates of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper

Dedication

This book is dedicated to my four sons — Benjamin, Nathan, Jacob, and Samuel. Thank you for never letting me forget that I am your dad.

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Contents

Part I. Description of Lean Manufacturing Chapter 1. Lean Manufacturing: A “Holistic” View..................................... 3 Chapter 2. Lean ManufacturingApproach ................................................... 7 Part II. Five Primary Elements Chapter 3. Organization Element ................................................................ 23 Chapter 4. Metrics Element .......................................................................... 35 Chapter 5. Logistics Element ...........................................................................