The 12 Principles of Manufacturing Excellence : A Lean Leaders Guide to Achieving and Sustaining Excellence, 2nd Edition

Following in the tradition of its bestselling predecessor, The 12 Principles of Manufacturing Excellence: A Lean Leader's Guide to Achieving and Sustaining Excellence, Second Edition outlines a comprehensive, proven process for delivering world-class performance while also cultivating the right culture through leadership, mentoring, and hourly associate involvement.

While most books on continuous improvement focus on specific tools and methods, this book details a top-down strategy and process that Lean leaders can use to implement and sustain manufacturing excellence. It outlines a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function.

This updated edition includes a new chapter on real stories about poor leadership at the top. Also featured are new and updated figures and exhibits. It contains chapters devoted to each principle of manufacturing excellence along with a chapter on each leader's role. Illustrating the importance of using Lean and Six Sigma tools to improve your business, the book:

• Details a comprehensive approach for achieving and sustaining excellence—from board room strategy to shop floor execution
• Integrates strategy and leadership development
• Paves a path for culture change that prepares hourly employees to take control of their processes and prepares management to enable them to do it
• Details an audit process for identifying priorities for improvement and tracking progress and ensuring sustainability

Tapping into more than four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve both vertical and horizontal alignment across your organization. Like the previous edition, the book includes a CD with color versions of the images in the book, a manufacturing excellence reading list, and formulas for selected metrics.

The CD also includes a sample manufacturing excellence audit (a powerful tool to achieve and sustain the journey), a sample communications plan, a sample communications plan calendar, a sample training plan, and a new Project Prioritization worksheet—all of which can be easily customized to meet your organization’s specific needs.

Foreword
Preface
Acknowledgments
Author

Chapter 1 : Leading the Revolution - From the Top

• Examples from the Arena
• It’s Not a Flavor of the Month—It’s Continuous Improvement
• An Example of Great CEO Leadership
• Who’s Running the Business?
• Shop Floor: What Impact Do Senior Leaders Have?
• Three Biggest Barriers
• For Success: Two Senior Leaders That Must Be in Place

Section I : 12 Principles of Manufacturing Excellence
Chapter 2 : The Manufacturing Excellence Strategy

• The Next Epiphany
• Origin of the 12 Manufacturing Principles
• The Manufacturing Excellence Strategy
• Common Metrics
• Manufacturing Excellence Audit

Chapter 3 : Manufacturing Principle 1 : Safety

• Plant Champion for Principle 1
• Stage Summary

Chapter 4 : Manufacturing Principle 2 : Good Housekeeping and Organization

• Stage Summary

Chapter 5 : Manufacturing Principle 3 : Authorized Formal Systems

• Stage Summary

Chapter 6 : Manufacturing Principle 4 : Preventive/Predictive Maintenance

• Stage Summary

Chapter 7 : Manufacturing Principle 5 : Process Capability

• Short-Term Actions
• Longer-Term Actions
• Stage Summary

Chapter 8 : Manufacturing Principle 6 : Product Quality

• Quality Systems Expertise
• Standard Work
• Stage Summary

Chapter 9 : Manufacturing Principle 7 : Delivery Performance

• Stage Summary

Chapter 10 : Manufacturing Principle 8 : Visual Management

• Why Visual Management?
• How Do You Know if Visual Management Is Effective?
• Visual Management Pictures
• Stage Summary

Chapter 11 : Manufacturing Principle 9 : Continuous Improvement

• The Playing Field Isn’t Level—Get Over It!
• Sample Questions When Touring a Plant for the First Time
• What about Benchmarking?
• Stage Summary

Chapter 12 : Manufacturing Principle 10 : Communication

• Why Aren’t Our Communications Effective?
• The Power of Communicating the Vision
• Stage Summary

Chapter 13 : Manufacturing Principle 11 : Training

• Management Has to Take Away the Excuses
• Find Out How Local Leadership Thinks and Acts
• Stage Summary

Chapter 14 : Manufacturing Principle 12 : Operator-Led Process Control

• The Day OLPC Was Born in My Mind
• Stage Summary

Section II : Leading Manufacturing Excellence
Chapter 15 : Plant Manager’s Role

• Other Things Good Plant Managers Expect
• Anticipation
• Initiative
• Timely Communications
• Feed Your Own Monkeys
• Develop Your Own Organization
• Properly Administer Company Policies
• Make the Numbers

Chapter 16 : Manufacturing Managers Role

• Have a Presence on the Shop Floor
• A Key Administrator of Company and Plant Policies
• Key Relationships with Peer Group
• The Manufacturing Manager Helps Set the Expectation for No Compromise to Quality Standards
• Interactions with Peer Group
• Responsibilities and Expectations

Chapter 17 : Materials Manager’s Role

• Production Control Office
• Sales and Operations Planning Process
• Purchasing or Sourcing
• Supplier Advisory Council
• Formal Systems Zealot
• Lean Zealot
• A Word about Cycle Times and Lead Times

Chapter 18 : Process Engineering Manager’s Role

• Engineering Staff
• Capital Appropriations
• Systems Infrastructure
• Process Engineer: A Key Team Member

Chapter 19 : Maintenance Manager’s Role

• Preventive Maintenance
• Rolling 3-Year Facility Maintenance Plan
• Maintenance Staffing

Chapter 20 : Quality Manager’s Role

• Technical Expert on Quality Improvement Tools
• Lead the Change from Firefighting to Fire Prevention
• Customer Advocate on Product Quality

Chapter 21 : Human Resources Manager’s Role

• Hourly Associate’s Voice
• Service-Oriented Staff of Experts
• Plant Manager’s Confidant
• Policy Administration
• Environmental Health and Safety
• Culture Change Zealot

Chapter 22 : The Finance Manager/Plant Controller's Role

• Establishing Rapport
• The Finance Managers Role with the Other Plant Staff Managers
• Keeper of the Metrics
• Capital Investment Watchdog
• Systems Integrity Zealot
• Shop Floor Visibility

Chapter 23 : Sustaining Manufacturing Excellence

• A Belden Plant Update
• Belden Lessons Learned in Retrospect
• About the Manufacturing Excellence Audit
• The Rest of the Story

Appendix A : The 12 Principles of Manufacturing Excellence
Appendix B : Manufacturing Excellence Audit
Appendix C : Manufacturing Excellence Reading List, 1986–2010
Appendix D : Formulas for Selected Metrics
Appendix E : Example of a Communications Plan Calendar
Appendix F : Example of a Training Plan
Appendix G : Project Prioritization Form
Index