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Card Based Control Systems for a Lean Work Design The Fundamentals of Kanban ConWIP POLCA and COBACABANA 1st Edition by Matthias Thurer, Mark Stevenson, Charles Protzman ISBN 1498746942 9781498746946

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Card Based Control Systems for a Lean Work Design The Fundamentals of Kanban ConWIP POLCA and COBACABANA 1st Edition Matthias Thurer Digital Instant Download

Author(s): Matthias Thurer, Mark Stevenson, Charles Protzman
ISBN(s): 9781498746946, 1498746942
Edition: 1
File Details: PDF, 2.30 MB
Year: 2016
Language: english
SKU: EB-5772412 Category: Tags: , ,

Card Based Control Systems for a Lean Work Design The Fundamentals of Kanban ConWIP POLCA and COBACABANA 1st Edition by Matthias Thurer, Mark Stevenson, Charles Protzman – Ebook PDF Instant Download/Delivery: 1498746942, 9781498746946
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ISBN 10: 1498746942 
ISBN 13: 9781498746946
Author: Matthias Thurer, Mark Stevenson, Charles Protzman

Many shops have simplified their production control by using card-based systems such as kanban and Constant Work-in-Process (ConWIP). Although these systems provide a simple and highly effective visual approach for controlling manufacturing and service operations, all too many shops struggle with failed implementations or achieve results that fall

Card Based Control Systems for a Lean Work Design The Fundamentals of Kanban ConWIP POLCA and COBACABANA 1st Table of contents:

Chapter 1: Basic Concepts
Highlights
What Is a Production/Service System?
The Customer
The Product/Service
Processes
Input (Supply)
Supplier
Level of Analysis
Supply Chain Management
Operations Management
Job Design
The Shop
The Shop Floor
A Station
What Is a Business Operation/Process?
Transforming Resources (Capacity)
Transformed Resources (Inventory and Work-in-Process)
Resource Requirements (Customer Demand)
A Card-Based Control System
What Does a Card-Based Control System Actually Control?
Waste
Categories of Waste
Types of Waste
Waste Migration
Variability
Uncertainty
Waste Reduction
Waste Allowance
Why Use a Card-Based Control System Rather than the Latest Technology?
Summary: What Card-Based Control Systems Do (And What They Do Not Do)
Highlights Revisited
Chapter 2: Basic Principles Underpinning a Card-Based Control System
Highlights
Input/Output Control
Stable Shop Floor
Stable Station
Efficient Process
Effective Process
Coordination by Standardization
Coordination by Plan
Coordination by Mutual Adjustment
Input/Output Control System
Pool
Order Release (Load-Limited)
WIP-Cap
Visualizing the Stability of the Shop Floor/Station: The Throughput Diagram
Throughput Diagram
Work-in-Process (Released Work)
Planned Work
Lead Time
Pool Time
Shop Floor Throughput Time
Summary: Input/Output Control Underpinning Card-Based Control
Highlights Revisited
Chapter 3: Simplified Scheduling through Pool Sequencing and a Shop Floor Dispatching Rule
Highlights
Pool Sequencing Rule (Pre-Shop Floor)
Dispatching Rule (Shop Floor)
Some Rules for Priority Dispatching on the Shop Floor
First-In-First-Out (FIFO)
Earliest Due Date (EDD)
Operation Due Date (ODD)
Shortest Processing Time (SPT)
Modified Operation Due Date (MODD)
Visualizing On-Time Performance: The Order Progress Diagram
Order Progress Diagram
Summary: Simplified Scheduling through Priority Dispatching
Highlights Revisited
Chapter 4: How to Diagnose a Control Problem?
Highlights
Criterion 1: Make/Produce/Assemble/Build/Serve, etc. To-Stock or To-Order
To-Stock
To-Order
To-Stock/To-Order Interface
Criterion 2: The Customer Penetration (Inventory/Order Separation) Point
Identity
Genidentity
Customer Penetration Point
Customization (Qualitative)
Customization (Quantitative)
Inventory/Order Separation Point
Inventory Control Problem
Order Control Problem
Decoupling Inventory
Inventory Decoupling Point
Criterion 3: Routing Characteristics
Routing
Layout
Criterion 4: Variability and Uncertainty in Resource Requirements
Workload Balancing (Heijunka)
Summary: Diagnosing the Control Problem
Highlights Revisited
Chapter 5: The Inventory Control Problem: Kanban Systems
Highlights
Kanban
Kanban System
Internal Supply Chain
Shop Floor Control
Kanban for the Internal Supply Chain: The Six Rules of Kanban Systems
First Kanban Rule
Second Kanban Rule
Third Kanban Rule
Fourth Kanban Rule
Fifth Kanban Rule
Sixth Kanban Rule
Work-in-Process Kanban vs. Production Kanban
Heijunka (Internal Supply Chain)
Kanban for Shop Floor Control
Direct Work(load)
Indirect Work(load)
Applicability of Kanban Systems
Summary: Kanban Systems
Highlights Revisited
Chapter 6: The Low Variability Order Control Problem: ConWIP
Highlights
Constant Work-In-Process (ConWIP)
ConWIP: How Does It Work?
ConWIP Rule 1
ConWIP Rule 2
The Applicability of ConWIP
Summary: ConWIP
Highlights Revisited
Chapter 7: Inventory Control Plus Material Requirements Planning for the Order Control Problem: POLCA
Highlights
Paired-Cell Overlapping Loops of Cards with Authorization (POLCA)
POLCA: How Does It Work?
Earliest Release Date (POLCA)
Material Requirements Planning
Applicability of POLCA
Blocking (in the Context of POLCA)
Summary: POLCA
Highlights Revisited
Chapter 8: How to Solve the High Variety Order Control Problem: COBACABANA
Highlights
Control of Balance by Card-Based Navigation (COBACABANA)
COBACABANA: How Does It Work?
Balancing Workloads: The Main Order Release Function of COBACABANA
Planning Board
Yamazumi Board
Workload Norm (WIP-Cap)
Order Guidance Form
COBACABANA Recognizes the Difference between Direct and Indirect Work
Aggregate Load (Used in COBACABANA)
Corrected Aggregate Load (Used in COBACABANA)
Simplifying the Need for Processing Time Estimations
COBACABANA and High Processing Time Variability: Starvation Avoidance
Starvation (or Idleness)
Unnecessary (or Premature) Idleness
Gateway Station
Premature Station Idleness and Order Release
Summary: COBACABANA
Highlights Revisited
Chapter 9: COBACABANA’s Card-Based System for Delivery Time Estimation
Highlights
Delivery Time Allowance
Card-Based Delivery Time Estimation: How Does It Work?
Customer Enquiry Management
Salesperson’s Display
COBACABANA as a Comprehensive System
Using the Salesperson’s Display for Output Control
Summary: COBACABANA’s Delivery Date Estimation Procedure
Highlights Revisited
Chapter 10: Summary: Framework of Applicability
Highlights
Loop Structure and Its Implications for the Application of Card-Based Systems
Card Properties and Their Implications for the Application of Card-Based Systems
The Need for IT Support and Its Implications for the Application of Card-Based Systems
Final Considerations: Nested Card-Based Control Systems
Nested Card-Based Control Systems
Implementation Information
References
Appendix: Summary of Card-Based Systems
Kanban Systems
Further Reading
The ConWIP System
Further Reading
The POLCA System
Further Reading
The COBACABANA System
Further Reading

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Matthias Thurer,Mark Stevenson,Charles Protzman,Control Systems,Work Design,Fundamentals,Kanban ConWIP POLCA,COBACABANA