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Preface | xi | |
Acknowledgments | xiii | |
Section 1 | Cellular Manufacturing--The Basics | |
Chapter 1 | Competing through Cellular Manufacturing | 3 |
Cellular Manufacturing--A Platform for Improvement | 4 | |
The Hard and Soft Sides of Cell Implementation | 7 | |
Change Seeks Company | 13 | |
The Organization of this Book | 13 | |
Chapter 2 | A Closer Look at Cells: What They Are and the Forms They Take | 17 |
Formal Definitions of Cellular Manufacturing | 17 | |
Four Perspectives on Cells | 22 | |
Related Types of Production Units | 26 | |
Operational Characteristics of Cells | 30 | |
The Relationship of Cellular Manufacturing to Other Organizational Principles | 37 | |
Chapter 3 | Why Cells Improve Performance | 45 |
Point of Departure for Performance Improvements | 45 | |
The Sources of Cell Benefits | 48 | |
Potential Disadvantages of Cells | 60 | |
Determining the Suitability of Cells | 63 | |
Section 2 | Adopting and Designing Cells | |
Chapter 4 | The Planning and Implementation of Cellular Manufacturing Systems | 71 |
The Planning and Implementation Process at a Glance | 71 | |
A 13-Step Blueprint for Your Planning Process--The Details | 74 | |
Chapter 5 | Factory Planning | 95 |
An Overview of Factory Planning | 95 | |
Confirming the Course | 99 | |
Understanding the Current Situation | 100 | |
Identifying Opportunities for Product Focus | 112 | |
Identifying Opportunities for Cells | 116 | |
Issues in Cell Design | 131 | |
Designing a New Factory Layout | 137 | |
Modifying the Infrastructure | 143 | |
Chapter 6 | Detailed Planning--One Cell at a Time | 147 |
Project Organization | 147 | |
Which Cell First? | 148 | |
Detailed Cell Planning--An Overview | 151 | |
Planning Block 1 | Cell Formation and Dimensioning | 151 |
Planning Block 2 | Management Systems | 156 |
Planning Block 3 | Employee, Layout, and Start-Up Issues | 157 |
Cell Dimensioning Revisited | 167 | |
Dilemmas in Cell Design and Layout | 172 | |
Chapter 7 | Understanding Cell Performance Using Modeling | 181 |
Models and Cell Design | 181 | |
What Is Manufacturing Lead Time? | 182 | |
Elementary Queuing Theory | 185 | |
Reducing Manufacturing Lead Time | 189 | |
Special Problems in Designing and Operating Cells | 193 | |
Queuing and Simulation Models--An Overview | 208 | |
The Value of Models and Modeling | 215 | |
Chapter 8 | Determining the Economic Value of Cells | 221 |
Strategic versus Economic Justifications | 222 | |
How to Cost-Justify Cells | 224 | |
Estimating the Costs and Benefits of Cellular Manufacturing | 226 | |
Discount Rates and Tax Considerations | 232 | |
Tangible and Intangible Costs and Benefits | 236 | |
Justifying Cells "After the Fact" | 238 | |
Some Practical Issues in Justifications | 240 | |
Section 3 | Designing the Cell System Infrastructure | |
Chapter 9 | Performance Measurement for Cells | 249 |
What Is a Performance Measurement System? | 250 | |
How to Generate Performance Measures | 253 | |
How to Evaluate and Present Performance Measures | 257 | |
The Process Performance Measurement Matrix | 266 | |
Measuring the Performance of Cells at Turner Products | 273 | |
Chapter 10 | Cost Accounting and Cellular Manufacturing | 281 |
Standard Costing Systems and Process Improvement--Are They Compatible? | 282 | |
How to Modify Your Costing System for Cellular Manufacturing | 291 | |
A "New" Cost Accounting System for Cells | 307 | |
Chapter 11 | Manufacturing Planning and Control Systems for Cells | 311 |
An Overview of Changes to MPC Practices Driven by Cell Adoption | 312 | |
MRP/ERP Systems | 313 | |
MPC Modifications Driven by Cells--Product Structures and Planning Horizon | 314 | |
MPC Modifications Driven by Cells--Capacity Management | 318 | |
MPC Modifications Driven by Cells--The Shop Floor Control System | 323 | |
MPC Modifications Driven by Cells--Controlling Material Flow through Pull Systems | 329 | |
Planning and Controlling Supplier Orders | 347 | |
MPC Modifications Driven by Cells--Lot-Sizing and Transfer Batching | 349 | |
MPC Modifications Driven by Cells--Product Sequencing | 352 | |
Choosing an MPC System for a Cellular Work Organization | 358 | |
Facilitating Planning and Control by Reducing Complexity | 365 | |
Chapter 12 | Job Design and Daily Work in Manufacturing Cells | 369 |
What Work Is Like in Cells | 369 | |
Do Jobs Change Automatically When You Implement Cells? | 373 | |
What Is Job Design? | 374 | |
Cell Work Characteristics | 375 | |
A Decision Framework for Cell Job Design | 381 | |
Cells and Teams | 389 | |
Supervision in Cell Systems | 393 | |
Chapter 13 | Selecting and Training Cell Employees | 401 |
Why Selection and Training Are Different with Cells | 401 | |
Selecting Cell Employees | 402 | |
Selecting Cell Supervisors and Cell Leaders | 419 | |
Training Cell Operators, Leaders, and Supervisors | 424 | |
Chapter 14 | Compensation Systems for Cell Employees | 437 |
Goals and Characteristics of an Ideal Cell Compensation System | 438 | |
Understanding Pay and Pay Systems | 442 | |
Compensation Systems Providing Regular Pay | 444 | |
Compensation Systems Providing Bonus Pay | 453 | |
Cell Compensation in Practice: Combining Pay Systems | 460 | |
An Ideal Cell Compensation System | 464 | |
Issues in Adopting and Implementing Compensation Systems for Cell Employees | 465 | |
Non-Monetary Rewards and Recognition | 468 | |
Section 4 | Implementing and Improving Cells | |
Chapter 15 | Planning for Cell Implementation and Managing the Change | 475 |
Planning for Cells in an Electronics Assembly Plant | 475 | |
Managing the Transition to Cells | 480 | |
The Role of Project Management in Cell Implementations | 491 | |
Chapter 16 | Common Problems in the Design, Justification, Implementation, and Operation of Cells | 513 |
Common Cell Design and Justification Problems | 514 | |
Common Problems in the Implementation of Cells | 523 | |
Common Problems During Cell Operation | 529 | |
Chapter 17 | Improvement and Evolution of Cells | 541 |
What Is Improvement? | 541 | |
Cells: An Ideal Setting for Continuous Process Improvement | 548 | |
Some Specific Strategies for Improving Cell Processes | 551 | |
Building a Culture of Continuous Improvement in Cells | 557 | |
Beyond Continuous Improvement--The Forces of Cell Evolution | 560 | |
Section 5 | Extending the Concept--Cells in the Office | |
Chapter 18 | Reorganizing Office Work Using Cellular Principles | 573 |
Office Operations--The Information Factory | 574 | |
What Are Office Cells? | 579 | |
Benefits of Office Cells | 587 | |
Potential Disadvantages of Office Cells | 593 | |
An Eight-Step Process for Designing Office Cells | 594 | |
14 Principles for Designing and Operating Office Cells | 604 | |
Making Office Cells Work: Infrastructure Issues and Other Key Challenges | 610 | |
Section 6 | What's Next? | |
Chapter 19 | Future Changes and Challenges | 621 |
A Brief Review | 621 | |
Cells in 2020: A Platform for Competitive Manufacturing | 622 | |
Gray Areas: Where We Need to Know More | 627 | |
Final Words | 628 | |
Appendices | ||
Appendix A | Using Standard Cost per Piece Data to Justify Cells | 629 |
Appendix B | How to Make Effective Presentations to Management | 633 |
Appendix C | Measurement Checklist | 635 |
Appendix D | A Primer on Accounting Systems | 637 |
Appendix E | Family Sequencing Procedures | 647 |
Appendix F | Job Enlargement and Job Enrichment | 655 |
Appendix G | Tips for Effective Cell Employee Selection Interviews | 661 |
Appendix H | A Sample of Courses Focused on Basic Cell Concepts, Interpersonal and Problem-Solving Skills, and Coaching and Facilitation | 663 |
Appendix I | One Company's Organizational Change Structure | 669 |
Appendix J | Process Improvement Opportunity Checklist from a Large Electronics Plant | 673 |
Appendix K | Guidelines for Implementing Setup Time Reduction | 677 |
Appendix L | A Primer on Functional Flow Charts and Tagging | 681 |
Endnotes | 687 | |
References | 723 | |
Index | 739 |
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