Cover image for Fast track to waste-free manufacturing : straight talk from a plant manager
Fast track to waste-free manufacturing : straight talk from a plant manager
Davis, John W., 1938-
Personal Author:
Publication Information:
Portland, Or. : Productivity Press, [1999]

Physical Description:
xxiv, 277 pages ; 24 cm
Format :


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TS169 .D38 1999 Adult Non-Fiction Central Closed Stacks

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Manufacturing in the United States is currently undergoing a major transition, yet large numbers of manufacturers simply do not recognize what it is all about. Many still operate under out dated manufacturing practices and do not see that the enemy is not the competition, but rather their own system of production. Batch, or mass manufacturing is still the preferred system of production for most U.S.-based industry. But to survive, let alone become globally competitive, companies will have to put aside their old mass manufacturing paradigms and completely change their entire production system.

WFM will give you step-by-step directions to making rapid, lasting changes. Davis has created 4 new drivers of WFM and has linked them so you know what order to do them in and when it is time to move to the next driver. He covers nearly every aspect of the lean revolution and provides essential tools and techniques you will need to implement WFM. He also addresses the critical management issues that will arise in any plant that is striving to be world class.

Drawing from more than 30 years of manufacturing experience, John Davis gives you tools and techniques for eliminating anything that cannot be clearly established as value added. WFM is not a theory. It is a proven process, and one the author has successfully implemented. He shares with you from his own experiences in guiding manufacturers through this process. Davis fully details the journey of a factory that moved from mass to waste-free manufacturing in a matter of 24 months. This factory was nationally recognized by wall street analysts as an effective manufacturing model. You get to sit in on their meetings and learn from their triumphs and failures.

So hold on to your hat, because you are about to learn how to do what most in the field of world class manufacturing tell you isn't possible: to rapidly deploy WFM and change the system of production. Filled with checklists, an ongoing case study and, most important, strategies that will work, Fast Track to Waste-Free Manufacturing: Straight Talk from a Plant Manager will provide you with the principles and methodology for WFM and a road map for its implementation. All you need is the will, the focus, and a sense of urgency about the future of U.S. manufacturing. If you are a plant manager, foreman, supervisor, or executive who wants to quickly transform your factory into a world class manufacturer, Mr. Davis' WFM methodology is "must reading."

A 296 minute abridged version of this book is also available on four compact discs or audio cassettes from Productivity Press.

Table of Contents

Publisher's Messagep. xiii
Acknowledgmentsp. xvii
Prefacep. xix
Introduction: The Revolution Has Just Begunp. 1
Chapter 1 Confronting the Deep Dark Dungeonp. 7
World Class Culture Shockp. 8
Changing the Lifestyle of a Factoryp. 10
Where Are Our Manufacturing Leaders?p. 11
The Old-Fashioned Production Meetingp. 14
What's Wrong with This Picture?p. 19
Chapter 2 The Plant Manager's Manifestop. 23
The Need to Energize for Changep. 23
The Critical Need for Renewed Focus by Today's Plant Managersp. 26
The Challenging Journey from Mass to Waste-Free Manufacturingp. 29
Overcoming the Conventional Cost of Doing Businessp. 32
How Strong Is Your Sense of Urgency?p. 33
The Fundamentals of Manufacturing Leadershipp. 35
Chapter 3 The New Competition and the Old Barriersp. 39
Month One, Day One--A New Assignmentp. 40
Old Barriers to Deploying Waste-Free Manufacturingp. 44
The Legend of the Loavesp. 47
Finding the Damaging Mental Barriersp. 51
Month One, Day Eight--Getting a Clearer Picturep. 53
Steps to Overcoming Old Barriersp. 55
Who the Heck Is Management?p. 57
Chapter 4 Waste-Free Manufacturing--Changing the Rulesp. 61
Four Key Drivers for Waste-Free Manufacturingp. 63
Driver 1 Workplace Organizationp. 63
Driver 2 Uninterrupted Flowp. 63
Driver 3 Error-Free Processingp. 64
Driver 4 Insignificant Changeoverp. 65
Some Very Important Differences between WFM and TPSp. 66
Tool Boxes to Support the Four Key Driversp. 67
Steps and Levels For 6Cp. 68
Pull Zones Rather Than Supermarketsp. 70
Month Seven--Not So World Classp. 72
Where to Begin--Understanding the Hidden Wastesp. 74
The Connection between Hidden Wastes and World Class Manufacturingp. 76
The Need for Never-Ending Improvementp. 79
Becoming Knowledgeable in the Lean Tools and Techniquesp. 80
The Ultimate Challenge Facing U.S. Manufacturersp. 81
Month Nine--The Awakeningp. 84
Chapter 5 Examining the WFM Driversp. 89
Month Twelve--Learning the Truthp. 89
Seeing a Better Way to Apply TPSp. 93
Driver 1 Workplace Organization (WPO)p. 95
How to Begin Implementing WPOp. 96
Establishing a Disposition Zonep. 98
Implementing 6Cp. 99
Achieving WPO Through Staircasing 6Cp. 101
An Imaginary Tour of a Fully Deployed WFMp. 104
Carrying the Momentum of WPO into the Office Arenap. 106
WPO as the Foundation for Continuous Improvementp. 106
Linking the Four WFM Driversp. 107
Shock Treatment Is Not Lasting Treatmentp. 108
There Is No Such Thing as a Perfect Factoryp. 111
Driver 2 Uninterrupted Flowp. 112
The First U-Flow Effort--Pick the Low-Hanging Fruitp. 114
How to Implement U-Flowp. 116
Aggressive Pursuit of Point-of-Use Manufacturing Applicationsp. 118
How Management Should Deal with Team Recommendationsp. 122
Driver 3 Error-Free Processingp. 124
Driver 4 Insignificant Changeoverp. 126
When Is Setup and Changeover Deemed Insignificant?p. 126
Getting Started with Insignificant Changeoverp. 128
A Second Look at Pull Zonesp. 128
Chapter 6 Beginning the WFM Journeyp. 133
The WFM Journey Is a Never-Ending Processp. 134
The Will to Change and the Pain Thresholdp. 135
Old Habits Don't Die Easilyp. 138
Takt Time-Producing to the Beatp. 139
Ten-Step Road Map for the Rapid Deployment of WFMp. 143
Step 1 Educating the Management Staffp. 145
Step 2 Implementing Workplace Organizationp. 145
Step 3 Establishing the Promotion Officep. 147
Step 4 Deciding on Your Core Processesp. 148
Step 5 Making Decisions Based on WFM Principlesp. 149
Step 6 Moving Equipment to Point-of-Usep. 150
Step 7 Transferring Inventory to Point-of-Usep. 150
Step 8 Limiting Parts Productionp. 150
Step 9 Instituting Product Cell Managementp. 151
Step 10 Linking the Four WFM Driversp. 152
Your Greatest Warriors Against Waste-Industrial Engineersp. 152
Simulating the Road Map to Deploy WFMp. 152
Month Fourteen-The Power of Whyp. 155
The Why Techniquep. 157
Chapter 7 Changing the Culturep. 161
The Production Worker Is the Center of Value-Addedp. 162
The Rules of the Game Have Changed for the Professional Ranksp. 163
Obsolete Best Business Practices of the Pastp. 164
Making the Union a Partner in Changep. 166
Building an Interface with the Union-Some Words of Advicep. 170
Month Fifteen-Storm Cloud Brewingp. 173
Work with Rather Than Deal with the Unionp. 176
Institutionalizing Owner-Operatorsp. 177
Championing a Cause for the Peoplep. 178
Month Eighteen-A Heated Issuep. 179
Using the Compressed Production System to Rapidly Deploy WFMp. 182
The Foundation of the Compressed Production Systemp. 184
Month Nineteen-Revitalizing the Morning Meetingp. 186
The One-Level Organizationp. 189
Chapter 8 Measuring Progress-What to Measure and Howp. 193
Ten Key Areas of Measurementp. 195
Measurement 1 Completeness of Production Processesp. 197
Measurement 2 Yield That Is Defect and Error Freep. 199
Measurement 3 Time Spent on Setup and Changeoverp. 200
Measurement 4 Skillfulness in the Work Forcep. 200
Measurement 5 Mistake-Proof Processesp. 200
Measurement 6 Mixed-Model Capabilityp. 201
Measurement 7 Waste Elimination Activitiesp. 201
Measurement 8 Elimination of Capital Expendituresp. 202
Measurement 9 Part Travel Distancep. 202
Measurement 10 Speed to Market for Product Enhancementsp. 203
Other Important Measurementsp. 203
Performance to Takt Timep. 203
Inventory Expressed in Pieces Rather Than Dollarsp. 204
Suppliers Certified for Delivery to Point-of-Usep. 205
Number of Value-Added Suggestions and Percent Implementedp. 206
Non-Value-Added-Essential Versus Nonessentialp. 206
Number of Repeat Visits to Equipment or Processingp. 207
Extent of Management Team Located on the Shop Floorp. 207
Value-Added versus Non-Value-Added Floor Space Utilizationp. 208
Total Square Footage of Manufacturing Space per Product Familyp. 208
Knowing What and When to Measurep. 209
Employee Reactions to Implementing New Measuresp. 209
Month Twenty-Making Both Steady Progress and Strong Enemiesp. 211
Give No Quarter and Take No Prisoners but Defuse Negative Perceptionsp. 214
Chapter 9 Organizational and Operational Issues to Support WFMp. 219
Launching the Compressed Production Systemp. 219
The Traditional Production Control Departmentp. 220
Eliminating the Traditional Quality Control Departmentp. 220
Analyzing Other Support Functions Under WFMp. 220
Month Twenty-One-Selecting a Champion for the Processp. 221
Establishing New Functions in the Compressed Production Systemp. 226
Applying WFM in the Office Environmentp. 227
How to Use Displaced Production Employeesp. 229
Chapter 10 Staying the Course on Your Never-Ending Journeyp. 235
A Race with No Finish Linep. 236
Month Twenty-Two-Gaining National Recognitionp. 237
The Continuous Improvement Pyramidp. 239
Layer 1- Establish and Fully Maintain WPOp. 241
Layer 2- Study and Analyze the Current Processp. 241
Layer 3- Plan and Lay out the New Processp. 242
Layer 4- Prove the New Processp. 243
Layer 5- Apply Visual Controlsp. 243
Understanding the Rocks and Boulders to Deploymentp. 244
Other Potential Bouldersp. 246
Fifteen-Point Checklist to Determine If You Are Globally Competitivep. 248
You Need the Will to Just Do It!p. 252
The Formula for Leading Effective Changep. 255
Six Common Paradigms in the Professional Ranks That Can Block Changep. 258
Month Thirty-Four-New and Grand Opportunitiesp. 260
WFM in the Automotive Industryp. 261
A Closing Comment on Your WFM Journeyp. 262
Bibliographyp. 265
About the Authorp. 267
Indexp. 269