Reorganizing the factory : competing through cellular manufacturing

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Title:

Personal Author:

Hyer, Nancy Lea, 1955-

Publication Information:

New York, NY : Productivity Pr., 2002

ISBN:

9781563272288

Subject Term:

Manufacturing cells

Production management

Added Author:

Wemmerlov, Urban

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ KL	30000010130006	TS155.8 H93 2002	Open Access Book	Book	Searching... Unknown

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

Author Notes

Nancy Lea Hyer is Associate Professor of Management at Vanderbilt University's Owen Graduate School of Management
Urban Wemmerlov is the Kress Family Wisconsin Distinguished Professor at the School of Business, University of Wisconsin-Madison

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

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Author Notes

Table of Contents