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Made to Order Lean, Excelling in High Mix Low Volume Manufacturing        By Greg Lane

With a Foreword by
John Shook.

Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix low volume manufacturing environments. While lean principles do apply, the implementation methods and tools, must be adapted and alternate methods embraced in a low-volume environment.

Made to Order Lean is specially geared to manufacturer's and service companies that have hundreds to thousands active parts of numbers/services with few or no ongoing forecasted volumes, and for job shops that build to order and want continuous process improvement. The primary focus is eliminating non-value added activities and instituting improvements on the most repetitive jobs a strategy that gives you more time to produce your low-volume work or one-offs.

This workbook is:

  • Based on Toyota methodology, Made to Order Lean explains how to implement critical adaptations to high mix low volume manufacturing.
  • Fully illustrated with actual examples and photos from successful applications in the high variation environments.
  • Comprehensive continuous process improvement, including an implementation Flow Chart that will help you to customize a transformation for your shop.
  • Written in a simple logical fashion by a former Toyota Employee with more than 15 years of hands-on experience.
This comprehensive book is a must-have for plant managers, manufacturing managers, and lean practitioners who need to apply lean principles effectively in their job shops, re-manufacture/repair, and high-mix, low-volume plants.
Table of Contents  
Foreword by John Shook Introduction: Method and Overview
Chapter 1: Managing Visually
Chapter 2: Management Auditing: Standardized Work for Managers.
Chapter 3: Associating a Time with All Work.
Chapter 4: Utilizing Day-by-Hour and FIFO Boards.
Chapter 5: Making Improvements When Youre Short of Capacity.
Chapter 6: Making Improvements When You Have Excess Capacity.
Chapter 7: Using Value Stream Mapping in a Low-Volume Environment.
Chapter 8: Making Man Power Improvements.
Chapter 9: Improving Machine Performance and Plant Layout.
Chapter 10: Making Improvements through Office Department Kaizen.
Chapter 11: Making Improvement through Office Process Kaizen.
Chapter 12: Improving your Product Costing
Glossary  
Index  
About the Author  
 

Praise for Made-to-Order Lean

“This book is an excellent resource for applying lean principles to the complex topic of high mix, low volume manufacturing, and is core reading material for those implementing a lean manufacturing system in this environment.”

- Paul A. Brent | General Director Global Supplier Quality and Development, Delphi Corporation
“Made-to-Order Lean provides clear and practical insights into how to increase competitiveness of a manufacturing facility. It will teach you how to increase the productivity of your operations through proper visual aides, improve quality and satisfy today's demanding customers.”

- Lee. C. Banks | Senior Vice President and Operating Officer, Parker Hannifin Corporation


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