Manufacturing Handbook of Best Practices: An Innovation, Productivity, and Quality Focus (St. Lucie Press Apics Series on Resource Management)

443 Pages·2001·8.25 MB·English

Manufacturing
Handbook of
Best Practices
An Innovation, Productivity,
and Quality Focus
© 2002 by CRC Press LLC
The St. Lucie Press/APICS Series on Resource Management
Titles in the Series
Applying Manufacturing Inventory Classification
Execution Systems Innovation: Paving the Way
by Michael McClellan for Electronic Commerce and
Vendor Managed Inventory
Back to Basics: by Russell G. Broeckelmann
Your Guide to
Manufacturing Excellence Lean Manufacturing:
by Steven A. Melnyk Tools, Techniques,
and R.T. “Chris” Christensen and How To Use Them
by William M. Feld
Enterprise Resources
Planning and Beyond: Macrologistics Management:
Integrating Your Entire A Catalyst for
Organization Organizational Change
by Gary A. Langenwalter by Martin Stein
and Frank Voehl
ERP: Tools, Techniques,
and Applications for Restructuring the
Integrating the Supply Chain Manufacturing Process:
by Carol A. Ptak Applying the Matrix Method
with Eli Schragenheim by Gideon Halevi
Integrated Learning Basics of Supply Chain
for ERP Success: Management
A Learning Requirements by Lawrence D. Fredendall
Planning Approach and Ed Hill
by Karl M. Kapp,
with William F. Latham Supply Chain Management:
and Hester N. Ford-Latham The Basics and Beyond
by William C. Copacino
Integral Logistics Management:
Planning and Control of Handbook of
Comprehensive Business Processes Supply Chain Management
by Paul Schönsleben by Jim Ayers
© 2002 by CRC Press LLC
Manufacturing
Handbook of
Best Practices
An Innovation, Productivity,
and Quality Focus
Edited by
Jack B. ReVelle, Ph.D.
ST. LUCIE PRESS
A CRC Press Company
Boca Raton London New York Washington, D.C.
© 2002 by CRC Press LLC
SL3003 FMFrame Page 4 Wednesday, November 14, 2001 3:02 PM
Library of Congress Cataloging-in-Publication Data
Manufacturing handbook of best practices : an innovation, productivity, and quality
focus / edited by Jack B. ReVelle
p. cm. -- (St. Lucie Press/APICS series on resource management)
Includes bibliographical references and index.
ISBN 1-57444-300-3
1. Technological innovations--Management. 2. Product management. 3. Quality
control. I. ReVelle, Jack B. II. Series.
HD45 .M3295 2001
658.5--dc21
2001048504
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International Standard Book Number 1-57444-300-3
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Table of Contents
Chapter 1 The Agile Enterprise............................................................................1
1.1 Introduction......................................................................................................1
1.2 Traditional Manufacturing...............................................................................2
1.3 Evolution from Lean to Agile Enterprise........................................................3
1.4 Agile Enterprise Foundation............................................................................5
1.4.1 Customer Focus....................................................................................5
1.4.2 Strategy Deployment............................................................................6
1.4.3 Focus on Work.....................................................................................7
1.5 Agile Manufacturing........................................................................................8
1.5.1 Definition..............................................................................................8
1.5.2 Agile Manufacturing Challenges in the Automotive Industry............8
1.6 Agile Enterprise Guiding Principles................................................................9
1.6.1 Benefits of Being Agile.......................................................................9
1.6.2 What’s New or Different?..................................................................10
1.7 Agile Enterprise Tools and Metrics...............................................................10
1.7.1 Transaction Analyses.........................................................................10
1.7.2 Activity/Cost Chains..........................................................................11
1.7.3 Organization Maps.............................................................................11
1.7.4 Key Characteristics (KCs).................................................................11
1.7.5 Contact Chains...................................................................................11
1.8 Customer Orientation.....................................................................................12
1.9 Information System Design...........................................................................13
1.10 Cooperation through Virtual Teams and Corporations..................................14
1.11 Highly Educated and Trained Workforce......................................................15
1.11.1 The Rise of the Knowledge Worker..................................................17
1.12 Agile Enterprise and the Internet..................................................................17
1.12.1 Supply Chain Challenges...................................................................18
1.12.2 Growth and Value...............................................................................19
1.12.3 Impact of the Internet on Various Aspects of Agility.......................19
1.12.4 Customer Orientation — The Rise of CRM
(Customer Relationship Management)..............................................20
1.12.4.1 What Will It Take to Keep the Customer
in the Future?......................................................................21
1.12.4.2 A Value Chain Proposition.................................................21
1.12.4.2.1 Functional Requirements..................................22
1.12.4.2.2 Reaping Business Benefits from IT.................23
1.12.4.2.3 Setting the Stage for Success...........................24
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1.12.5 The Future of the Agile Enterprise....................................................24
1.12.5.1 Idea-Centric Society...........................................................24
1.12.5.2 The Agile Enterprises of the Future Will Have
Certain Defining Characteristics.........................................25
1.12.5.2.1 Management by Web........................................25
1.12.5.2.2 Information Management.................................25
1.12.5.2.3 Mass Customization.........................................25
1.12.5.3 Dependence on Intellectual Capital...................................26
1.12.5.4 Global..................................................................................26
1.12.5.5 Speed...................................................................................26
1.12.6 Flexible Facilities and Virtual Organizations....................................26
Chapter 2 Benefiting from Six Sigma Quality...................................................27
2.1 A Brief History of Quality and Six Sigma...................................................27
2.2 How Six Sigma Affects The Bottom Line....................................................31
2.3 Characteristics of a Six Sigma Organization................................................32
2.3.1 Customer Focus..................................................................................33
2.3.2 Everybody on the Same Page............................................................34
2.3.3 Extensive and Effective Data Usage..................................................34
2.3.4 Empowerment: Autonomy, Accountability, and Guidance...............35
2.3.5 Reward Systems that Support Objectives..........................................35
2.3.6 Relentless Improvement.....................................................................36
2.4 Departmental Roles and Responsibilities......................................................36
2.4.1 Top Management................................................................................37
2.4.2 Cost Accounting.................................................................................39
2.4.3 Information Technology.....................................................................39
2.4.4 Human Resources..............................................................................39
2.4.5 Factory Management..........................................................................40
2.4.6 Sales and Marketing...........................................................................40
2.4.7 Engineering and Design.....................................................................40
2.4.8 Quality................................................................................................41
2.4.9 Other Organizations...........................................................................41
2.5 Individual Roles and Responsibilities...........................................................41
2.5.1 Executive Staff...................................................................................41
2.5.2 Coordinator.........................................................................................43
2.5.3 Champions..........................................................................................43
2.5.4 Problem-Solving Practitioners, Experts, and Masters.......................43
2.5.5 Team Members and Supervisors........................................................44
2.6 Six Sigma Implementation Strategies............................................................44
2.6.1 Assess Current Situation....................................................................45
2.6.2 Establish Accountability and Communication..................................46
2.6.3 Identify and Sequence Tasks.............................................................46
2.6.4 Performance Metrics..........................................................................46
2.7 Conclusion......................................................................................................47
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Chapter 3 Design of Experiments.......................................................................49
3.1 Overview........................................................................................................49
3.2 Background....................................................................................................49
3.3 Glossary of Terms and Acronyms.................................................................50
3.4 Theory............................................................................................................51
3.5 Example Applications and Practical Tips......................................................52
3.5.1 Using Structured DOEs to Optimize Process-Setting Targets..........52
3.5.2 Using Structured DOEs to Establish Process Limits........................53
3.5.3 Using Structured DOEs to Guide New Design Features
and Tolerances....................................................................................53
3.5.4 Planning for a DOE...........................................................................53
3.5.5 Executing the DOE Efficiently..........................................................56
3.5.6 Interpreting the DOE Results............................................................56
3.5.7 Types of Experiments........................................................................57
3.6 Before the Statistician Arrives.......................................................................61
3.7 Checklists for Industrial Experimentation.....................................................64
References................................................................................................................68
Chapter 4 DFMA/DFSS......................................................................................69
4.1 Design for Manufacture and Assembly (DFMA).........................................69
4.1.1 Simplicity...........................................................................................70
4.1.2 Use of Standard Materials Components and Designs.......................71
4.1.3 Specify Tolerances.............................................................................71
4.1.4 Use of Common Materials.................................................................72
4.1.5 Concurrent Engineering Collaboration..............................................72
4.2 Design for Six Sigma (DFSS).......................................................................73
4.2.1 Statistical Tolerance Analysis............................................................73
4.2.2 Process Mapping................................................................................73
4.2.3 Six Sigma Product Scorecard............................................................76
4.2.4 Design to Unit Production Cost (DTUPC).......................................82
4.2.5 Designed Experiments for Design Optimization..............................84
Chapter 5 Integrated Product and Process Development...................................87
5.1 Overview........................................................................................................87
5.2 Background....................................................................................................87
5.2.1 Design-Build-Test..............................................................................87
5.2.2 Teams Outperform Individuals..........................................................88
5.2.3 Types of Teams..................................................................................88
5.2.4 Fad of the Early 1990s.......................................................................88
5.2.5 DoD Directive 5000.2-R (Mandatory Procedures for Major
Defense Acquisition Programs).........................................................89
5.2.5.1 Benefits of IPPD.................................................................89
5.2.5.2 Why IPPD Benefits Employees..........................................90
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5.2.5.3 Why IPPD Benefits the Customer......................................90
5.2.5.4 Why IPPD Benefits an Organization.................................91
5.3 Organizing an IPT..........................................................................................91
5.3.1 Initial Challenges — What Are We Doing (Goals)?
Why Change? How Are We Going to Do It (Roles)?......................91
5.3.1.1 Goals...................................................................................91
5.3.1.2 Why Change?......................................................................92
5.3.1.3 Roles...................................................................................92
5.3.2 Core Members (Generalists) vs. Specialists (Bit Players)................92
5.3.3 Collocation and Communication Links.............................................93
5.3.4 Team Culture......................................................................................93
5.3.5 Picking the Right Team Leader.........................................................94
5.4 Building the Environment (Culture) for Successful IPPD............................94
5.4.1 Effective Change Management..........................................................94
5.4.1.1 Fear and Jealousy of Change (from the Functional
Manager’s View).................................................................95
5.4.1.2 Organizational Issues Created by Change.........................95
5.5 The Tools that an IPT Will Require..............................................................96
5.5.1 Technical Tools..................................................................................96
5.5.2 Communication and Decision-Making Tools....................................96
5.6 Probable Problem Areas, and Mitigations.....................................................96
5.6.1 Reduced Development Time = Less Time for Corrections
and Customer Review and Feedback................................................96
5.6.1.1 Customer Inputs..................................................................97
5.6.1.2 Specification Errors............................................................97
5.6.2 “Silo” and “Group-Think” Mentality................................................97
5.6.3 Self-Sufficient vs. Too Large a Team................................................97
5.6.4 Recruiting — Internal (Why Were They Chosen?) vs. External......98
5.6.5 Retention and Career Paths Following Project Completion.............98
5.6.6 Costs Associated with IPTs...............................................................99
5.7 Methodologies of Simultaneous Product and Process Development.........100
5.7.1 Concept and Prototyping.................................................................100
5.7.2 Design and Development.................................................................100
5.7.2.1 CAD Databases.................................................................101
5.7.2.2 Codevelopment.................................................................101
5.7.2.3 Tooling (Molds and Dies)................................................101
5.7.2.4 Passive Assurance in Production......................................102
5.7.3 Qualification.....................................................................................102
5.7.3.1 Tooling Qualification........................................................102
5.7.3.2 Design Verification First...................................................103
5.7.3.3 Assembly Qualification = Product Qualification.............103
5.7.4 Conclusion........................................................................................104
5.8 Internet Sites................................................................................................104
References..............................................................................................................104
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Chapter 6 ISO 9001:2000 Initiatives................................................................107
6.1 Introduction..................................................................................................107
6.2 The Basic Changes.......................................................................................108
6.3 Quality Management System.......................................................................110
6.3.1 Quality Management System Audit Checklist Based
on ISO 9001:2000 Clause 4............................................................113
6.4 Management Responsibility.........................................................................113
6.4.1 Management Responsibility Audit Checklist Based
on ISO 9001:2000 Clause 5............................................................115
6.5 Resource Management.................................................................................115
6.5.1 Resources Management Audit Checklist Based
on ISO 9001:2000 Clause 6............................................................115
6.6 Product Realization......................................................................................115
6.6.1 Product Realization Audit Checklist Based
on ISO 9001:2000 Clause 7............................................................119
6.7 Measurement, Analysis, and Improvement.................................................119
6.7.1 Measurement Analysis and Improvement Audit Checklist
Based on ISO 9001:2000 Clause 8.................................................121
6.8 Disclaimer....................................................................................................121
Appendices.............................................................................................................122
Chapter 7 ISO 14001 and Best Industrial Practices.........................................141
7.1 Introduction..................................................................................................141
7.2 Energy Use...................................................................................................142
7.2.1 Lighting............................................................................................142
7.2.1.1 Recommendations and Guidelines...................................142
7.2.2 Ventilation........................................................................................143
7.2.2.1 Recommendations and Guidelines...................................143
7.2.3 Electrical Equipment and Machinery..............................................144
7.2.3.1 Recommendations and Guidelines...................................144
7.2.3.1.1 Computers and Printers..................................144
7.2.3.1.2 Photocopy Machines......................................144
7.2.3.1.3 Stand-Alone Refrigerators and Freezers........145
7.2.3.1.4 Dishwashers....................................................145
7.2.3.1.5 Point-of-Use Water Heating...........................145
7.2.4 The Solar Option..............................................................................145
7.3. Other Environmental Impacts......................................................................145
7.3.1 Use of Water.....................................................................................146
7.3.1.1 Recommendations and Guidelines...................................146
7.3.1.1.1 Inside Buildings..............................................146
7.3.2 Boilers..............................................................................................148
7.3.2.1 Recommendations and Guidelines...................................148
7.3.2.1.1 Optimizers.......................................................148
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7.3.3 Waste................................................................................................148
7.3.3.1 Recommendations and Guidelines...................................148
7.3.3.1.1 Permits............................................................148
7.3.3.1.2 Waste Reduction Initiatives............................149
7.3.3.1.3 Waste Water (See Also, Water Use)...............149
7.3.3.2 General..............................................................................150
7.3.4 Recycling..........................................................................................150
7.3.4.1 Recommendations.............................................................150
7.3.5 Ozone-Depleting Substances...........................................................152
7.3.5.1 Recommendations and Guidelines...................................152
7.3.5.1.1 Refrigeration and Air Conditioning...............153
7.3.5.1.2 Dry Cleaning..................................................153
7.3.5.1.3 Fire Protection Systems..................................154
7.3.6 Hazardous Substances......................................................................154
7.3.6.1 Recommendations and Guidelines...................................154
7.3.6.1.1 Acids...............................................................154
7.3.6.1.2 Alkalis.............................................................154
7.3.6.1.3 Bleach.............................................................154
7.3.6.1.4 Solvents...........................................................155
7.3.6.1.5 Phosphates......................................................155
7.3.7 Stationery and Office Supplies........................................................156
7.3.7.1 Recommendations and Guidelines...................................157
7.3.8 Office Equipment — Fixtures and Fittings.....................................157
7.3.8.1 Recommendations and Guidelines...................................157
7.3.9 Transport..........................................................................................158
7.3.9.1 Recommendations and Guidelines...................................158
7.3.9.1.1 Servicing.........................................................159
7.3.9.1.2 Training and Driving Style.............................159
7.3.9.1.3 Vehicle Use.....................................................159
7.3.10 External Influences...........................................................................160
7.3.10.1 Recommendations and Guidelines...................................160
7.3.11 Miscellaneous...................................................................................160
7.3.11.1 Recommendations and Guidelines...................................160
7.4 Environmental Management Initiatives.......................................................160
7.4.1 Energy Management Systems..........................................................160
7.4.1.1 Responsibility...................................................................160
7.4.1.2 Energy Audit.....................................................................161
7.4.1.3 Action Plan.......................................................................161
7.4.1.4 Involve Employees............................................................161
7.4.1.5 Finance..............................................................................162
7.4.1.6 Energy Monitoring............................................................162
7.4.1.7 Yardsticks..........................................................................162
7.4.1.8 Consumption Targets........................................................163
7.4.2 Access to Legislative Information...................................................163
7.4.2.1 Recommendations and Guidelines...................................163
© 2002 by CRC Press LLC