World Class Manufacturing The Next Decade

Since the invention of double-entry bookkeeping, managers have judged a company's worth by sales and profits. Now, Richard J. Schonberger, the architect of the worldwide Just-In-Time revolution, reaches beyond "financials" to redefine excellence -- and reveals, with new benchmark data, how pioneers become dynasties. Schonberger's pathbreaking new research reveals that, from 1950 to 1995, while "financials" dipped and soared repeatedly, industrial decline and ascendancy correlated perfectly with inventory turnover -- one of two key nonfinancial indicators and a bedrock measure, along with customer satisfaction, of a company's power, strength, and value. In this immensely readable book, he captures these new metrics -- the true predictions of future success -- in 16 customer-focused principles created from self-scored reports supplied by over 100 pioneering manufacturers in nine countries. Armed with new world-class benchmark data, Schonberger redefines excellence in terms of competence, capability, and customer-focused, employee-driven, data-based performance. For front-tine associates to senior executives, Schonberger has written manufacturing's action agenda for the next decade. This book will be indispensable reading for manufacturing and general managers in all industries, as well as for pension fund managers, institutional investors, stock analysts, and stockbrokers.

In his best-selling book Japanese Manufacturing Techniques, Richard J. Schonberger revolutionized American manufacturing theory and, more important, practice. In that breakthrough book, he revealed that Japanese manufacturing excellence was not culturally bound. Offering the first demystified explanation of the simple techniques that fueled Japan's industrial success, he demonstrated how the same methods could be put to work as effectively in U.S. plants.

In 1996, Richard Schonberger's WORLD CLASS MANUFACTURING: THE NEXT DECADE, winner of the Shingo Prize for manufacturing research, presented eye-catching results. Manufacturing firms had reached peaks of excellence and promised that there was more to come. Now, in his most important work yet, Schonberger rings the warning bell: record profits are covering up waste and weakness and companies must act now or fall prey to low-cost upstarts in China, the Near East, and Latin America. Schoenberger reveals that by the critical standard of lean production, shedding inventories, nearly seventy five percent of the world's leading manufacturers, including General Electric, General Motors and Toyota, have stopped improving. Amidst prosperity, these companies have inventories that are bursting at the seams. With upstarts around the world waiting to pounce, Schonberger argues that these companies need shock treament now. His revolutionary four part success formula shows manufacturers how to create Dynamic Tech Centres that develop or acquire new products, eliminate manufacturing wastes, simplify and standardize production and move production abroad for high volume manufacturing.

This book tells 101 stories of company efforts to implement the many aspects of flow manufacturing -- including such topics as just-in-time production, total quality control, reorganization of factories into product-focused or customer-focused cells, plants-in-a-plant, material flows by the simplicity of visual kanban, supplier partnerships, quick setup of equipment, cross-training and job rotation of the work force, and many more. The 101 mini-case studies – dubbed "caselets" -- include 26 non-U.S. companies from 12 countries and cover a wide swath of industrial sectors, and include many well-known corporations such as Apple, Campbell Soup, Honeywell, and Boeing. From the 1980s to the present, the author has been taking the message of process improvement and customer-focused excellence far and wide. Most of these travels, usually in connection with delivering a seminar, include brief factory tours in which he compiled detailed notes and then organized them as brief reports — his unvarnished analysis or take on what they do well and what needs improvement. In the main the reports were then sent back to the hosts of the plant tour. These factory tours and these follow-up reports form the basis of the large majority of this book’s caselets. Many of the caselets bring to life process-improvement methodologies in detail. With lots of caselets to draw from, the readers will find vivid examples of similar companies and processes within their respective industries. For example, the caselets often include applications of advanced concepts in cost management, employee training, performance management, supply chains, and logistics as well as applications of plant layout, quick setup, material handling, quality assurance, scheduling, ergonomics, and flow analysis.

The differences between the United States and Mexico may be immense, but their links—economic, political, and social—are profound, and growing stronger. In this incisive narrative, John Adams argues that Mexico, with which the United States shares a 1,951 mile border, is no sideshow but a pivotal component of American economic health and regional security. The primary theme that runs throughout this book is that Mexico has historically had, and will continue to e Drawing from the most current economic and demographic data and business examples, Adams demonstrates the depth and breadth of U.S.-Mexican relations, and their implications for American business and policymaking. In the process, he dispels popular myths about Mexico as an economic backwater or political distraction. The result is an authoritative and colorful account of our complex relationship with our neighbor to the south, and its broader implications for global growth and political stability. The border between the United States and Mexico runs for 1,951 miles. The differences between the two nations may be immense, but their links—economic, political, and social—are profound, and growing stronger. In this incisive narrative, John Adams argues that Mexico is no sideshow, but a pivotal component of American economic health and regional security. The primary theme that runs throughout the book is that Mexico—its domestic growth and industrial capacity, population pressures, energy needs, political dynamics, and strategic location—has historically had, and will continue to have, a tremendous impact on the United States. Drawing from the most current economic and demographic data and business examples, Adams demonstrates the depth and breadth of U.S.-Mexican relations and their implications for American business and policymaking. A unique aspect of the book is his analysis of the competition between Mexico and China for American resources for investment, trade, and economic development. Adams also dispels popular myths about Mexico as an economic backwater or political distraction. The result is an authoritative and colorful account of our complex relationship with our neighbor to the south—and its broader implications for global economic growth and political stability.

The Lean concepts and principles described in this book have revolutionized manufacturing practice and business conduct in a manner similar to what Henry Ford’s system did for mass manufacturing. Lean production however, involves much more than the adoption of methods and procedures, it requires a change in management philosophy that emphasizes relationship building, trust, and responsibility being conferred to frontline workers and suppliers. Based on three decades of teaching experience, Lean Production for a Competitive Advantage: A Comprehensive Guide to Lean Methodologies and Management Practices introduces the Lean philosophy and illustrates the effective application of Lean tools with real-world case studies. From fundamental concepts to integrated planning and control in pull production and the supply chain, the text provides a complete introduction to Lean production. Coverage includes small batch production, setup reduction, pull production, preventive maintenance, standard operations, as well as synchronizing and scheduling lean operations. Detailing the key principles and practices of Lean production, the text also: Illustrates effective implementation techniques with case studies from a range of industries Includes questions and completed problems in each chapter Explains how to effectively partner with suppliers and employees to accomplish productivity goals Designed for students who have a basic foundation in production and operations management, the text provides a thorough understanding of the fundamental principles of Lean. It also offers practical know-how for implementing a culture of continuous improvement on the shop floor or in the office, creating a heightened sense of responsibility and pride in all stakeholders involved, and enhancing productivity and efficiency to improve the bottom line. Instructor’s material available – please contact: [email protected] or call 1-800-634-7064 to request these materials.

The most thorough, valid set of findings on global manufacturing and winning practices worldwide This eye-opening resource sets a new standard for how manufacturing practices are viewed in today's business world. The results of an extensive research project spanning 164 factories in the United States, Japan, Germany, Italy, and the United Kingdom determine the best path to high performance manufacturing. This is one of the first books to offer comparisons of manufacturing in these five countries, addressing their current issues and providing insights that affect manufacturing worldwide. Researchers from such universities as the London Business School, Wake Forest University, Yokohama University, and the University of Minnesota detail how manufacturing leaders are raising the bar on practices in product development, organizational alignment, quality management, and more. Covering the vital areas of machinery, electronics, and auto components, they examine the most effective methods and techniques across a host of functions within manufacturing-looking at how everything from new technology and information systems to human resource practices and manufacturing strategy should be introduced into a plant environment to achieve high performance manufacturing. Using data from companies such as Texas Instruments, Honda, Sony, Prince, John Deere, and Caterpillar, High Performance Manufacturing takes a comprehensive view by showing how to select and integrate the practices that best fit a plant's particular situation-the most critical and difficult task to achieve in practice. With its strong research base and high caliber of contributors, this unique volume will inspire managers of any country or industry to set their own path to high performance manufacturing.