Manufacturing excellence : renewal and rebirth

154 Pages·2015·3.576 MB·English

by  McKay, Kenneth N., Wiers, Vincent C.S

EBOOKS Manufacturing Excellence M
C ENGINEERING MANAGEMENT
FOR THE Renewal and Rebirth K
A COLLECTION
ENGINEERING Y
Kenneth N. McKay • Vincent C.S. Wiers

LIBRARY • C.M. Chang, Editor
W
Create your own Hello, I’m Jake, a retired production planner. I’ve been talking to my IE
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Customized Content coffee mate Ben about the factory where I have spent the b etter part S
of my life. Believe me, I have seen things go well and even more go
Bundle  — the more
very wrong. I’m outside the gate now, but the grapevine is keeping
books you buy,
me up to date. Which is why I know that the factory is h eading into
the higher your
oblivion, as management does not seem to u nderstand common
discount!
sense principles and they are testing the patience of their main
customer. But wait, things look like they might change when new
THE CONTENT
management is brought in. This new plant manager might change
• Manufacturing things around, and thanks to my old friends we can keep on top of
Engineering things. Do you want to hear my story?
• Mechanical
The concepts imbedded in the factory’s journey capture the
M
& Chemical leading practices in progressive and proactive management. Manufacturing
Engineering a
The  common sense concepts embody the philosophy of
n
• Materials Science
collaboration, shared fate, mutual respect, and leveraging the u
Excellence
& Engineering f
intellectual capital that exists in each and every factory. This book is a
• Civil & for you if you want your factory to survive and thrive! c
t
Environmental u Renewal and
Engineering Kenneth N. McKay is a professor of management sciences at the r
i
• Advanced Energy University of Waterloo, Waterloo Canada. He has several d ecades of n
g
Technologies research and consulting experience in manufacturing management Rebirth
including such topics as Lean, quality processes, supply chain E
x
THE TERMS management and production control. Since 2003 he has been c
focusing on Japanese manufacturing management techniques and e
• Perpetual access for l
the next stage in Japan’s manufacturing journey. le
a one time fee
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• No subscriptions or Dr. Vincent C.S. Wiers is an expert in planning complex c
e
access fees manufacturing operations. He works as a consultant at Twinlog
• Unlimited and as a researcher at Eindhoven University of Technology. His
concurrent usage academic expertise lies in the human factor in production control
• Downloadable PDFs and he has published his work in several academic journals, such
• Free MARC records as the Journal of Operations Management, Production Planning &
Control, and the International Journal of Operations and Production Kenneth N. McKay
For further information, Management.
a free trial, or to order,
Vincent C.S. Wiers
contact: 
[email protected]
ISBN: 978-1-60650-851-0
MANUFACTURING
EXCELLENCE

MANUFACTURING
EXCELLENCE
R R
enewal and ebiRth
KENNETH N. MCKAY AND
VINCENT C.S. WIERS
MOMENTUM PRESS, LLC, NEW YORK
Manufacturing Excellence: Renewal and Rebirth
Copyright © Momentum Press®, LLC, 2015.
All rights reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means—
electronic, mechanical, photocopy, recording, or any other—except for
brief quotations, not to exceed 400 words, without the prior permission
of the publisher.
First published by Momentum Press®, LLC
222 East 46th Street, New York, NY 10017
www.momentumpress.net
ISBN-13: 978-1-60650-851-0 (print)
ISBN-13: 978-1-60650-852-7 (e-book)
Momentum Press Engineering Management Collection
Collection ISSN: 2376-4899 (print)
Collection ISSN: 2376-4902 (electronic)
Cover and interior design by Exeter Premedia Services Private Ltd.,
Chennai, India
10 9 8 7 6 5 4 3 2 1
Printed in the United States of America
To Erik

a
bstRact
For years, automotive supplier GAFFER has been able to survive using its
old management and production practices. But times have been changing
and GAFFER’s future looks bleak. Jake is a retired production plan-
ner, reflecting on his long history with the GAFFER factory and what is
currently happening. He wonders how things might change as their main
customer wants a completely new part to be not only produced, but also
designed at GAFFER. Just when the old management is about to mess
up the relationship with the customer, there is a new factory manager. He
starts turning the factory around and Jake shares all of the juicy stories
with his coffee mate, Ben.
KEYWORDS
change management, collaborative design, management training, manu-
facturing management, operational excellence, organizational knowledge,
people development, quality management, supply chain management,
teamwork

c
ontents
Forewords xi
PreFace xiii
acknowledgments xv
chaPter 1 IntroducIng Ben 1
chaPter 2 Ben and Jake 5
chaPter 3 strategy 9
chaPter 4 the Instrument cluster 15
chaPter 5 Fear 21
chaPter 6 mr. BIg Intervenes 29
chaPter 7 the contract 37
chaPter 8 culture shock 43
chaPter 9 the grIm reaPer 49
chaPter 10 the new Boss 53
chaPter 11 the good, the Bad, and the ugly 59
chaPter 12 shared Fate 65
chaPter 13 what makes a lIne a good lIne? 71
chaPter 14 settIng examPles 77
chaPter 15 see the lIght 83
chaPter 16 teachIng the BasIcs 89
chaPter 17 the new IncentIve scheme 95