The 12 principles of manufacturing excellence : a leader's guide to achieving and sustaining excellence

294 Pages·2015·11.257 MB·English

by  Fast, Larry E

S E C O N D E D I T I O N
The 12 Principles
of Manufacturing
Excellence
A LEAN LEADER'S
GUIDE TO
ACHIEVING
AND SUSTAINING
EXCELLENCE
S E C O N D E D I T I O N
The 12 Principles
of Manufacturing
Excellence
A LEAN LEADER'S
GUIDE TO
ACHIEVING
AND SUSTAINING
EXCELLENCE
Larry E. Fast
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
S E C O N D E D I T I O N
The 12 Principles
of Manufacturing
Excellence
A LEAN LEADER'S
GUIDE TO
ACHIEVING
AND SUSTAINING
EXCELLENCE
Larry E. Fast
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2016 by Larry E. Fast
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20150518
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Dedication
To my parents, Marge and “Rebel,” and to my children, Jennifer and Scott,
who have been the inspiration for most of the good things I’ve done in my life.
In this second edition I also want to recognize the hundreds of leaders
over my 35 years in the arena who have shared the vision for excellence
and led their teams accordingly; the thousands, mostly hourly associates,
who have trusted, believed, and followed while offering their own great
ideas for improvement; and those who led and participated in the impor-
tant work of team problem solving. There are far too many to mention
here, but they and I know who they are. Sincere thanks, one and all.

Contents
Foreword .............................................................................................xiii
Preface ...................................................................................................xv
Acknowledgments ...............................................................................xix
Author .................................................................................................xxv
Chapter 1 Leading the Revolution—From the Top ...........................1
Examples from the Arena...........................................................4
It’s Not a Flavor of the Month—It’s Continuous
Improvement ................................................................................8
An Example of Great CEO Leadership ....................................9
Who’s Running the Business? ..................................................11
Shop Floor: What Impact Do Senior Leaders Have? ............12
Three Biggest Barriers ...............................................................13
For Success: Two Senior Leaders That Must Be in Place ......14
SeCtion i 12 Principles of Manufacturing excellence
Chapter 2 The Manufacturing Excellence Strategy ........................19
The Next Epiphany ....................................................................25
Origin of the 12 Manufacturing Principles ...........................27
The Manufacturing Excellence Strategy ...............................28
Common Metrics ......................................................................32
Manufacturing Excellence Audit ............................................32
Chapter 3 Manufacturing Principle 1: Safety ..................................39
Plant Champion for Principle 1 ..............................................42
Stage Summary .........................................................................44
Chapter 4 Manufacturing Principle 2: Good Housekeeping
and Organization .............................................................47
Stage Summary ..........................................................................57
vii
viii • Contents
Chapter 5 Manufacturing Principle 3: Authorized Formal
Systems ..............................................................................59
Stage Summary ..........................................................................63
Chapter 6 Manufacturing Principle 4: Preventive/Predictive
Maintenance .....................................................................65
Stage Summary .........................................................................68
Chapter 7 Manufacturing Principle 5: Process Capability .............71
Short-Term Actions ...................................................................73
Longer-Term Actions ................................................................78
Stage Summary ..........................................................................83
Chapter 8 Manufacturing Principle 6: Product Quality .................85
Quality Systems Expertise ......................................................86
Standard Work ...........................................................................87
Stage Summary ..........................................................................89
Chapter 9 Manufacturing Principle 7: Delivery Performance .......91
Stage Summary ..........................................................................94
Chapter 10 Manufacturing Principle 8: Visual Management ..........97
Why Visual Management? .......................................................97
How Do You Know If Visual Management Is Effective? .....98
Visual Management Pictures ..................................................99
Stage Summary ........................................................................103
Chapter 11 Manufacturing Principle 9: Continuous Improvement .....105
The Playing Field Isn’t Level—Get Over It! .........................105
Sample Questions When Touring a Plant for the First
Time ..........................................................................................108
What about Benchmarking? ..................................................109
Stage Summary ........................................................................110
Chapter 12 Manufacturing Principle 10: Communication .............113
Why Aren’t Our Communications Effective? .....................113