In this first comprehensive departure from the time-and-motion dictums of Frederick Taylor's Shop Management that have influenced management practices for most of this century, Kiyoshi Suzaki offers a framework for successfully conducting business at its most crucial point-the shop floor. Drawing on the principles of holistic management, where organizational boundaries are smashed and co-destiny is created, Suzaki demonstrates how modern shop floor management techniques -- focusing maximum energy on the front line -- can lead to dramatic improvements in productivity and valueadded-to-services. The role of management today, Suzaki argues, is to eliminate its own responsibilities by thinking of the organization from the genba, or shop floor, point of view. In this challenge, Suzaki claims, organizations need to collect the wisdom of people by practicing "Glass Wall Management," where organizations become transparent, enabling employees to contribute maximum creativity as opposed to blocking their potential with what he calls "Brick Wall Management." Further, to empower individuals to selfmanage their work and satisfy their customers, Suzaki asserts that they all should learn to manage their own "mini-company," where everybody is considered president of his or her area of responsibility. Front-line supervisors, Suzaki shows, must develop a mission and goals and share them both up and downstream. He cites examples of the "shop floor point of view" -- McDonald's Corporation's legal staff learning how to sell hamburgers and fix milkshake machines; Honda's human resource staff training on the assembly line -- that narrow the gap between top management and the shop floor. By upgrading people's skills, focusing on empowerment, and streamlining processes, Suzaki illustrates that an organization will realize concrete improvements in quality, cost, delivery, safety, morale, and ultimately, its competitive position.

Modern manufacturing is more advanced than ever. There are too many moving parts between human errors, equipment breakdowns, delayed shipments, and hurried orders. Errors are inevitable without adequate planning. Preplanning, planning, staffing, directing, monitoring, and controlling actions that improve shop efficiency and analysis are all parts of shop floor management. The process of converting raw resources (inputs) into the intended output (products or services) is referred to as production or operations activity. Production is a collection of consecutive tasks that generate a desirable product that customers will accept and that also satisfies their needs in terms of quantity and intended use. Using effective production planning and control, the goals can be attained. Smart manufacturers are swiftly implementing the most recent business process optimization techniques in response to the changing production environment, and shop floor management is probably the most crucial technique on the list. A shop floor is a place where production or assembly is done. Either the labor would have to do this manually, or sophisticated automated systems would have to do it. Consequently, shop floor management might be characterized as management at the point of action. At this location where value is created, managers and production staff gather every day to thoroughly examine the machinery, inventory, storage, and manufacturing processes in order to spot any disruptions or deviations in the value-added processes and, where appropriate, to start corrective action.

In recent years there has been a tremendous upsurge of interest in manufac turing systems design and analysis. Large industrial companies have realized that their manufacturing facilities can be a source of tremendous opportunity if managed well or a huge corporate liability if managed poorly. In particular industrial managers have realized the potential of well designed and installed production planning and control systems. Manufacturing, in an environment of short product life cycles and increasing product diversity, looks to tech niques such as manufacturing resource planning, Just In Time (lIT) and total quality control among others to meet the challenge. Customers are demanding high quality products and very fast turn around on orders. Manufacturing personnel are aware of the lead time from receipt of order to delivery of completed orders at the customer's premises. It is clear that this production lead time is, for the majority of manufacturing firms, greatly in excess of the actual processing or manufacturing time. There are many reasons for this, among them poor coordination between the sales and manufacturing function. Some are within the control of the manufacturing function. Others are not.

Shop floor control and namely the problem of job shop scheduling have been fields of research for a long time. However, until now no comprehensive framework on the various aspects exists. This book will provide a systems perspective towards shop floor control by stressing its sociotechnical and cybernetical nature. It focuses on the behavioral aspects of control activities and sees the shop floor as the center of value-adding manufacturing activities within an enterprise. The book enables the reader to understand the interaction of organization, information technology and human resources. This eventually allows to achieve holistic and agile solutions and facilitates profound organizational change. The book will therefore provide a welcome addition to several standard textbooks on the issue.

Annotation "In his book, Verkerk investigates the shop floor processes of modern factories. Two ethnographical case studies are presented from the perspective of a factory manager. He shows that high-trust and high-power relations between management and employees are the basic conditions for responsible, accountable, and successful organisations. In a philosophical argument, he develops an ethics of responsibility combining the ideas of humanity, trust and power on the shop floor, and the normative development of organisational structures."--BOOK JACKET. Title Summary field provided by Blackwell North America, Inc. All Rights Reserved.

Foreword. . . Foreword. . Ch. 1. The journey begins. 5. Ch. 2. Introducing Dr. Shigeo Shingo. 15. Ch. 3. Taichi Ohno. 27. Ch. 4. Defining waste. 39. Ch. 5. Dr. Shingo asking five whys at Granville Phillips. 45. Ch. 6. My first trip to Japan : a thriller. 49. Ch. 7. Discovering Shingo : a magic moment. 63. Ch. 8. The lobster feast and the first changeover by Dr. Shingo. 71. Ch. 9. The study mission process. 85. Ch. 10. SMED - quick changeovers - the heart of JIT. 93. Ch. 11. My mental transformation : there are 'gems' scattered all over Japan. 103. Ch. 12. Developing an understanding of Japan. 121. Ch. 13. Factory tours : a feast for the eyes. 127. Ch. 14. The Gemba walk. 137. Ch. 15. 5 S. 143. Ch. 16. Discovering books in Japan. 147. Ch. 17. Fire the quality manager!. 155. Ch. 18. The best factory in the world. 161. Ch. 19. Getting to know Dr. Shingo. 171. Ch. 20. The birth of the Kaizen Blitz. 177. Ch. 21. Finding books and meeting Kazuhiro Uchiyama. 187. Ch. 22. Shingo to teacher. 193. Ch. 23. Never take no for an answer. 197. Ch. 24. Introduction to TPM - another billion dollar idea. 201. Ch. 25. Shigehiro Nakamura. 213. Ch. 26. Kaoru Ishikawa. 227. Ch. 27. Iwao Kobayashi - 20 keys. 231. Ch. 28. Union of Japanese scientists and engineers (JUSE). 235. Ch. 29. Dr. W. Edwards deming. 237. Ch. 30. The impact of Dr. Joseph Juran. 251. Ch. 31. Life time employment system. 253. Ch. 32. Quick and easy Kaizen. 257. Ch. 33. A gallery of great geniuses. 277. Ch. 34. Professor Louis E. Davis and socio-technical systems. 295. Ch. 35. Failure to change is a vice!. 301. Ch. 36. Summary. 305. Ch. 37. Gary Convis - President Toyota (TMMK). 307. Ch. 38. Gary Smuda - technicolor corporation. 319. Ch. 39. Professor Doc - Robert Hall. 329. Ch. 40. Don Dewar - President QCI International. 341. Ch. 41. Richard Schonberger. 345. Ch. 42. Vision statements. 355. . Lean terms. 361.

This book presents practical approaches for facilitating the achievement of excellence in the management and leadership of organizational resources. It shows how the principles of creating shared value can be applied to ensure faster learning, training, business development, and social renewal. In particular, it presents novel methods and tools for tackling the complexity of management and learning in both business organizations and society. Discussing ontologies, intelligent management systems, methods for creating knowledge and value added, it offers novel insights into time management and operations optimization, as well as advanced methods for evaluating customers’ satisfaction and conscious experience. Based on two conferences, the AHFE 2018 International Conference on Human Factors, Business Management and Society, and the AHFE 2018 International Conference on Human Factors in Management and Leadership, held on July 21–25, 2018, in Orlando, Florida, USA, the book provides both researchers and professionals with new tools and inspiring ideas for achieving excellence in various business activities. Chapter “Convolutional Gravitational Models for Economic Exchanges: Mathematical Extensions for Dynamic Processes and Knowledge Flows” is available open access under a Creative Commons Attribution 4.0 International License via link.springer.com.

Winner of the 2003 Shingo Prize! Reorganizing work processes into cells has helped many organizations streamline operations, shorten lead times, increase quality, and lower costs. Cellular manufacturing is a powerful concept that is simple to understand; however, its ultimate success depends on deciding where cells fit into your organization, and then applying the know-how to design, implement and operate them. Reorganizing the Factory presents a thoroughly researched and comprehensive "life cycle" approach to competing through cellular work organizations. It takes you from the basic cell concept and its benefits through the process of justifying, designing, implementing, operating, and improving this new type of work organization in offices and on the factory floor. The book discusses many important technical dimensions, such as factory analysis, cell design, planning and control systems, and principles for lead time and inventory reduction. However, unique to the literature, it also covers in depth the numerous managerial issues that accompany organizing work into cells. In most implementations, performance measurement, compensation, education and training, employee involvement, and change management are critically important. These issues are often overlooked in the planning process, yet they can occupy more of the implementation time than do the technical aspects of cells. Includes: Why do cells improve lead time, quality, and cost? Planning for cell implementation Justifying the move to cells, strategically and economically Designing efficient manufacturing and office cells Selecting and training cell employees Compensation system for cell employees Performance and cost measurement Planning and control of materials and capacity Managing the change to cells Problems in designing, implementing, and operating cells Improving and adapting existing cells Structured frameworks and checklists to help analysis and decision-making Numerous examples of cells in various industries

Survival and thriving in today’s business environment require companies to continuously strive for operational excellence at all levels of the organization. Simply working to maintain existing operations is not an adequate or sustainable business strategy, especially when competing in a global market. To remain relevant, companies must adopt a process control and continuous improvement mentality as an integral part of their daily work activities. These two operational disciplines form the foundation and stepping stones for manufacturing excellence. Processes must be stable, capable, and controlled as a prerequisite for sustainable improvement. Sustainable improvements must be strategic, continuous, and focused on process optimization. Modern-day manufacturing is rapidly changing in the face of technological, geopolitical, social, and environmental developments. These challenges are altering the way we think and act to transform raw materials into finished goods. Meeting these challenges requires particular attention to how we develop and engage people and apply technology for long-term sustainability and competitive advantage. This book takes you on a journey to explore the fundamental elements, management practices, improvement methods, and future direction of shop floor management. Part 1 of this five-part manuscript considers workplace culture, organizational structure, operational discipline, and employee accountability as the foundation for a robust manufacturing system. Part 2 studies the impact of process standardization, data analytics, information sharing, communication, and people on daily shop floor management. Once the management system has been adequately described, Part 3 concentrates on its effective execution, monitoring, and control with a deep look into the people, methods, machines, materials, and environment that make it possible. Like every good manufacturing text, efficiency and productivity are key topics. That’s why Part 4 explores various methods, tools, and techniques associated with product and process development, productivity improvement, agile methods, shop floor optimization, and manufacturing excellence. The final section, Part 5, shifts focus to emerging technologies, engaging the reader to contemplate technology’s impact on the digital transformation of the manufacturing industry.