Cover image for Cost reduction and optimization for manufacturing and industrial companies
Title:
Cost reduction and optimization for manufacturing and industrial companies
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Publication Information:
Canada : Wiley-Scrivener, 2010
Physical Description:
viii, 258 p. : ill. ; 24 cm.
ISBN:
9780470609576
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30000010222421 TS165 B47 2010 Open Access Book Book
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30000010222420 TS165 B47 2010 Open Access Book Book
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Summary

Summary

Focuses on rapid implementation of practical, real-world cost reduction solutions

In today's economic climate, the need to cut costs can be the difference between success and failure. Cost Reduction and Optimization for Manufacturing and Industrial Companies covers all major cost reduction areas, providing easy to read examples and advice on steps to take. It provides the roadmap for implementing recommended actions with true and tried methods by taking a modern, all-inclusive look at manufacturing processes. Based on the author's cost reduction experience gained during 30 years of senior operations and consulting engagements with hundreds of organizations, this book includes easy-to-understand and easy-to-implement cost reduction concepts organized into five general areas --labor, material, design, process, and overhead.

Each chapter:

Dives into a cost reduction area and starts with the bottom line first by summarizing key points Provides proven tactics for cutting costs without a lot of extraneous data Follows a qualitative and design-oriented approach Emphasizes quick implementation and measurable cost reduction Identifies who in the organization should do the work Outlines risks and suggested risk mitigation actions Contains numerous tables, graphs, and photos to show the concepts described in the book

Praise for Cost Reduction and Optimization for Manufacturing and Industrial Companies

"In this introductory book, Berk not only takes a modern, all-inclusive look at manufacturing processes but also provides substantial coverage of engineering materials and production systems. It follows a more qualitative and design-oriented approach than other texts in the market, helping readers gain a better understanding of important concepts. They'll also discover how micro-economic conditions relate to the process variables in a given process as well as how to perform manufacturing science and quantitative engineering analysis of manufacturing processes."
-- Fred Silverman , Director Engineering of Hi-Shear Technology Corporation

"Joe Berk has created a unique, practical and straightforward approach to cost reduction in manufacturing. This work provides valuable insights and concrete techniques, based on real-world experiences, to any manufacturing organization undertaking change to position itself to compete successfully in the global marketplace."
-- Joe Carleone , President and COO of American Pacific Corporation

Check out author Joseph Berk's blog at http://manufacturingtraining.wordpress.com


Author Notes

Joseph H. Berk holds a graduate degree in mechanical engineering from Rutgers University and an MBA from Pepperdine University. His work is focused on helping organizations improve their engineering, manufacturing, and process capabilities, with a special emphasis on identifying and eliminating the causes of delinquent deliveries, product failures, excessive cost, and in efficient practices. Joe's work encompasses a wide set of industries including electronics, electro-optical, aerospace, automotive, biomedical, marine, ordnance, consumer goods, water treatment, metal fabrication, and the US Department of Defense.


Table of Contents

Introductionp. 1
Chapter 1 Organizing a Cost-Reduction Programp. 3
Part I Laborp. 15
Chapter 2 Defining Headcount and Controlling Staff Growthp. 17
Chapter 3 Developing and Implementing Time Standardsp. 28
Chapter 4 Measuring and Using Efficiencyp. 36
Chapter 5 Assessing Machine Utilizationp. 45
Chapter 6 Controlling Overtimep. 52
Chapter 7 Making Multiple Shifts Productivep. 61
Chapter 8 Finding and Reducing Lost Timep. 67
Chapter 9 Using the Learning Curve to Drive Costs Downp. 76
Part II Materialp. 87
Chapter 10 Make-versus-Buy Determinationsp. 89
Chapter 11 Inventory Minimizationp. 100
Chapter 12 Material Utilizationp. 110
Chapter 13 Minimizing Supplier Costsp. 117
Chapter 14 Supplier Negotiationp. 125
Chapter 15 Supplier Competitionp. 133
Part III Process Improvementsp. 139
Chapter 16 Workflow Optimizationp. 141
Chapter 17 Setup Time Reductionp. 151
Chapter 18 Material-Handling Improvementsp. 160
Chapter 19 Scrap and Rework Reductionp. 166
Chapter 20 Work Center Cleanlinessp. 178
Part IV Designp. 185
Chapter 21 The Design Approachp. 187
Chapter 22 Requirements Relaxationp. 194
Chapter 23 Tolerance Relaxationp. 199
Chapter 24 Materials Substitutionp. 207
Chapter 25 Packagingp. 211
Part V Overheadp. 219
Chapter 26 General Overhead Expensesp. 221
Chapter 27 Travelp. 231
Chapter 28 Inspectionp. 236
Paxt VI Gaining Disciples and Measuring Progressp. 245
Chapter 29 Suggestion Programsp. 247
Chapter 30 Measuring Progressp. 253
Indexp. 255