Table Of ContentBusiness Management B Results-Based
Ü
T
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Results-Based Systematic Operational Improvement brings you a new
N
perspective, and more significantly, provides benefits by the application of E
Systematic Operational
R
this systematic methodology. This book provides a complete set of practical
improvement techniques. More importantly, it guides you to identify the
appropriate tools to use for each circumstance, how to use the tools, and how to
target them directly to achieve effective results. R Improvement
e
s
Results-Based Systematic Operational Improvement presents a systematic u
method of improvement. This straightforward method is easy to understand. It lt
s
is based on fundamentals. It is universally applicable to any type of business. -
B
This book assembles the different ideas, processes, and techniques under the
a
same roof, to develop a systematic methodology that is easily understandable s
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and applicable.
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Part I discusses productivity for businesses that have monitored their deficiencies. y
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It specifically provides definitions of results-based improvement and the t
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systematic method with regard to improvement planning to raise awareness from m
the perspective of the employees. a
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i
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Part II takes you through the Systematic Improvement Planning pattern. Systematic
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Improvement Planning consists of a pattern of six steps through which each p
project passes, and the three fundamentals involved in any improvement project. e
r
The book describes step by step the procedure and improvement techniques to a
t
use. Each chapter is devoted to a specific step of the pattern. i
o
n
a
Whether you desire to achieve improvement for yourself, for your team, or for
l
your business, Results-Based Systematic Operational Improvement provides I
m
a detailed framework regarding systematic improvement planning. The method
p
and its techniques, example cases, and working forms guide you through r
o
preparing the improvement plan of your existing or future business. It has been v
e
designed to be specific, simple to understand, and easy to use.
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Results-Based Systematic
Operational Improvement
http://taylorandfrancis.com
Results-Based Systematic
Operational Improvement
Dr. Hakan Bütüner
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2017 by Taylor & Francis Group, LLC
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Library of Congress Cataloging‑in‑Publication Data
Names: Bütüner, Hakan, author.
Title: Results-based systematic operational improvement / Hakan Bütüner.
Description: Boca Raton : Taylor & Francis, CRC Press, 2017. | Includes bibliographical
references.
Identifiers: LCCN 2016043698 | ISBN 9781498726306 (hardback : alk. paper)
Subjects: LCSH: Operations research. | Continuous improvement process.
Classification: LCC T57.6 .B885 2017 | DDC 658.4/034--dc23
LC record available at https://lccn.loc.gov/2016043698
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To my dear Mother, the only one who always
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http://taylorandfrancis.com
Contents
Preface xi
author xv
Part I ImProvement PlannIng
chaPter 1 results-Based ImProvement 3
1.1 Productivity 4
1.1.1 Importance of Productivity for Businesses 6
1.1.2 Relationship between Profitability and Cost 7
1.2 Results-Based Improvement 8
chaPter 2 results-Based systematIc ImProvement
PlannIng 11
2.1 SIP: Approach 15
2.2 SIP: Three Fundamentals 16
2.3 SIP: Six Steps 16
2.3.1 Organize the Program and Investigate
the Current Status by Data Analysis 17
2.3.2 Clarify Improvement Targets 18
2.3.3 Understand Analysis and Determine
Operational Leverages 18
2.3.4 Develop Alternative Improvement Ideas 19
2.3.5 Evaluate Ideas and Select the Best 19
2.3.6 Implementation Plan of Selected
Improvements and Control 19
vii
viii Contents
Part II stePs of systematIc
ImProvement PlannIng
chaPter 3 organIze the Program and InvestIgate
the current status By data analysIs 23
3.1 Improvement Program Organization 25
3.2 Planning Issues, External Conditions, and Program
Schedule 26
3.3 Review the Current Situation 26
chaPter 4 clarIfy ImProvement targets 31
chaPter 5 understand analysIs and determIne
oPeratIonal leverages 37
5.1 Measurement and Analysis Techniques 39
5.1.1 Analytical Quality Tools 40
5.1.1.1 Pareto Diagram (for Root Cause
Analysis) 40
5.1.1.2 Cause-and-Effect Diagram 41
5.1.1.3 Control Tables 44
5.1.1.4 Histograms 46
5.1.1.5 Distribution Diagrams 47
5.1.1.6 Control Sheets 47
5.1.2 Work Sampling 48
5.1.3 Work Study 51
5.1.4 Flow Process Chart/Activity Analysis Chart 54
5.1.5 Sequence Diagram 56
5.1.6 Customer Surveys 57
5.1.7 Financial Analysis 60
5.1.8 Process Analysis 60
5.1.9 Capacity Analysis 66
5.1.10 5W 70
5.2 Determination of Operational Leverages 72
5.2.1 Problems According to Their Appearance 73
5.2.2 Determining Possible Operational
Improvement Leverages 73
chaPter 6 develoP alternatIve ImProvement Ideas 77
6.1 Process of Idea Development 78
6.1.1 Generation of Ideas for Improvement 78
6.1.2 Description of Ideas 80
6.2 Operational Improvement Techniques 83
6.2.1 Layout Planning—Systematic Layout Planning 84
6.2.2 Materials Handling Planning—Systematic
Handling Analysis 86
6.2.3 Container Planning—Systematic Container
Planning 87
6.2.4 Planning and Process Improvements 88
Contents ix
6.2.5 Cell Design—Systematic Planning of Cells 89
6.2.6 Group Technology 93
6.2.7 Line Balancing 96
6.2.8 Just-in-Time Production 97
6.2.9 Single-Minute Exchange of Die 98
6.2.10 Kanban 99
6.2.11 Error Prevention (Poka-Yoke) 99
6.2.12 5S 105
6.2.13 Total Productive Maintenance 111
6.2.14 Kaizen 113
chaPter 7 evaluate ImProvement Ideas and select
the Best ones 117
chaPter 8 ImPlementatIon Plan of selected
ImProvements and control 123
8.1 Implementation Plan 124
8.2 Monitoring and Evaluation 125
aPPendIx 131
references 161
Index 163
