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Factory physics for managers : how leaders improve performance in a post-lean six sigma world /

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From the award-winning developers of Factory Physics, a leadership guide for breakthrough productivity. In the past, executive management of operations has typically involved a hodgepodge of copycat initiatives, mathematics and software--and hoping for the best. Factory Physics for Managers provides...

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Bibliographic Details
Main Author: Pound, Edward S.
Other Authors: Bell, Jeffrey H., Spearman, Mark L.
Format: Book
Language:English
Published: New York : McGraw-Hill Education, [2014]
Subjects:
Production management.
Factory management.
BUSINESS & ECONOMICS > Production & Operations Management.
Online Access:Contributor biographical information
Publisher description
Table of Contents:
  • Machine generated contents note: The Book in Brief
  • Why Is This Book Needed?
  • ch. 1 Science---Use It or Lose
  • Of Theories and Buzzwords
  • Toyota and Science
  • How Toyota Did It
  • Batch and Queue Production
  • A Balanced Approach
  • The Track Record: Lean and Six Sigma
  • A Confused Landscape
  • Boeing's Moving Assembly Line
  • Looking Ahead
  • ch. 2 The Nature of Business---A Secret Hidden in Plain Sight
  • Leading Performance Improvement More Productively
  • Tradeoff Illustrations
  • Leadership and Tradeoffs
  • The Factory Physics Approach
  • ch. 3 Practical Science for Leaders
  • Knowledge and Science
  • Science, Math, Software, and Intuition
  • Practical Theory
  • The Value Stream: Demand, Stocks, and Production
  • Buffers
  • Types of Buffers
  • Conceptual Illustrations: Something or Someone Is Always Waiting
  • A Manager's World: Environment, Tactics, Controls, and Measures
  • Putting Practical Science to Practice
  • Definitions.
  • Contents note continued: Factory Physics Science: As Simple as Possible but No Simpler
  • Advancing the Practical Science of Management
  • The VUT Equation
  • Cycle Time versus Utilization Graph
  • Production and Stocks
  • Little's Law
  • Production-Flow Graph
  • Variance of Replenishment-Time Demand Equation
  • Tradeoff Plot: Inventory versus Fill Rate Graph
  • Efficient Frontiers
  • Insights from the Tradeoff Plot
  • Visual Management of Stock-Point Performance
  • Stocks and Flows, the Lot-Size Graph
  • ch. 4 Practical Math for Managers
  • Defining Terms
  • Modeling Stocks
  • A Perfect World
  • Replenishment Times
  • Demand
  • Forecast Error and Lead Time
  • Inventory Performance Measures
  • Computing Inventory Policies
  • Inventory in an Assembly System
  • Modeling Flows
  • Little's Law
  • Capacity Analysis
  • Overall Equipment Effectiveness
  • Best-Case Performance
  • Effect of Variability
  • Measures of Variability
  • Queuing Effects
  • Total Cycle Time.
  • Contents note continued: Raw Process Time
  • Move Time
  • Shift-Differential Time
  • Batch Time
  • Pull Systems
  • Combining Stocks and Flows
  • Cash-Flow Optimization
  • Examples of Cash-Flow Optimization
  • Conclusions
  • ch. 5 Profit, Cash Flow, and Factory Physics Science
  • The Value-Added Fantasy
  • Financial Statements and the Science of Operations
  • Financial Performance Driven by the Science of Operations
  • Contribution Margin at the Bottleneck
  • When Lean Manufacturing Adds Cost
  • Inventory Optimization
  • Managing the Portfolio of Buffers
  • Marketing and Operations Strategies Drive Financial Results
  • ch. 6 Operations Strategy and Planning
  • Operations Strategy
  • Strategy
  • Tactics
  • Controls
  • Measures
  • Execution
  • Information Technology Control and Control Limits
  • Factory Physics Sales and Operations Planning
  • S & OP Event Sequence and Participants
  • S & OP Meeting Practices
  • S & OP+
  • S & OP+ Process.
  • Contents note continued: ch. 7 Implementing Tactics, Controls, and Measures for Optimal Results
  • Demand Tactics and Controls
  • Describing and Forecasting Demand
  • Lumpy Demand
  • Inventory Tactics
  • Inventory Strategy Considerations
  • Capacity Considerations
  • Current Performance versus Predicted Performance
  • Strategic Options
  • Tactics for Inventory Management
  • Inventory Control
  • Capacity Tactics
  • Utilization
  • WIP Control and CONWIP
  • Virtual Queues and Due-Date Quoting
  • Rework and Scrap
  • Response-Time Stratagems
  • Predictive Control Using MRP/ERP Systems
  • Common Practices
  • MRP for Inventory Control
  • MRP for Production Control
  • Dynamic Risk-Based Scheduling
  • Dynamic Risk-Based Scheduling in Assemble-to-Order Environments
  • Measures Alignment and Insight
  • ch. 8 Leadership, Measures, and Culture Change
  • An Approach to Sustainable Leadership
  • A High-Level Plan So That Strategies Can Be Shared and Understood
  • Vision and Mission.
  • Contents note continued: Critical Strategies
  • Monthly or Quarterly Plans to Establish Prioritized Initiatives
  • Inventory Optimization
  • Utilization Targets
  • Weekly Scheduling Meetings to Plan the Work
  • WIP Caps
  • Due-Date Quoting
  • Weekly Operations Meetings to Check Progress
  • Daily Mechanisms for Feedback
  • Personal Plans So That Individuals Understand Their Roles
  • ch. 9 Examples from Industry
  • Learning to See---Farther
  • Beyond ABC---Optimal Inventory Policies
  • Reducing Cycle Times in a Traditional Pharmaceutical Plant
  • Restoring Customer Service in a Fabrication and Assembly Plant
  • Increasing Throughput in a Biopharmaceutical Facility
  • Dynamic Risk-Based Scheduling in the Textile Industry
  • ch. 10 Final Word on Factory Physics Science (for Now)
  • Quick Wins
  • Operations Strategy Alignment with Business Strategy
  • Absolute Benchmarking
  • High-Level Assessment of Utilization
  • Bottleneck Analysis
  • Potential for WIP Cap Deployment.
  • Contents note continued: High-Level Analysis of Lead Times
  • ERP/MRP Mechanics
  • More Complex Implementations
  • A Large Company Implementation
  • Alternative Histories
  • The Future.