Build-to-Order & Mass Customization; The Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory [Hardcover]

David M. Anderson (Author)

Book Description

Publication Date: July 1, 2008

This 2008 book will show how to: Build any product, standard or mass-customized, on-demand without forecasts or inventory. Simplify supply chains to resupply spontaneously, rather than trying to manage complex supply chains that order and wait for parts. Achieve substantial cost advantages from eliminating inventory and many overhead costs. Revolutionize company business models with evolutionary self-supporting steps for dramatic growth of revenue and profits.

This book will be extremely valuable for manufacturers that have any of these challenges:

Customization. Craft customizing is slow, expensive, and hard to maintain quality. Customizing by mass production is inefficient and compromises the other production.

Product Variety. Build-to-forecast producers sell products from inventory. As variety increases, it gets harder to keep enough of every variation in stock to satisfy demand.

Unreliable Forecasts. Forecast accuracy decreases dramatically as variety and market volatility increase, which are both rising.

Inventory Problems. Selling products from inventory creates many problems: out-of-stocks, obsolescence, write-offs, inventory carrying costs, and discounting unsold inventory.

Response time. Manufacturers of products or industrial parts may try to build products to-order but will not be able to deliver them quickly if they have to wait for parts, setup changes, and equipment availability.

Editorial Reviews

Review

"An outstanding and practical navigation guide for the complex task of implementing mass customization." -- Harold Pinto, President, Fire Rescue Group, Federal Signal Corp.

"Like all of the other books by Dr. Anderson, 'Build-to-Order & Mass Customization' is excellent." -- Dr. E. Ray Ladd, Professor, Master of Engineering Management Program, Washington State University

About the Author

Dr. Anderson is the world's leading expert on showing companies how to build standard and mass-customized products on-demand without forecasts or inventory.

His first book on this subject was Agile Product Development for Mass Customization (1997, McGraw-Hill). Dr. Anderson was appointed guest editor for the Mass Customization issue of the Agility Forum's journal, Agility & Global Competition (Vol. 2, No. 2, Spring 1998).

Starting in 1989, he has facilitated the Suzaki/SME video program, Techniques for Continuous Improvement, on eliminating waste, reducing lead times, implementing flow, improving productivity, and reducing setup, batch size, and inventory.

He taught two courses on BTO for the Association for Manufacturing Excellence (AME), after which he lead two AME plant tours at Hoffman Engineering, which, based on Dr. Anderson s principles, build a $30,000,000 plant to build on-demand a wide variety of mass-customized and standard sheet-metal enclosures.

He also wrote the book on DFM, literally and figuratively: Design for Manufacturability & Concurrent Engineering; How to Design for Low Cost, Design in High Quality, Design for Lean Manufacture, and Design Quickly for Fast Production ; (2008, CIM Press). At the Management of Technology Program at the University of California at Berkeley, he created and taught the course New Product Development.

His book-length website is on the subject, Half Cost Products, with that title as the URL.

Dr. Anderson has over 35 years of industrial experience and has trained many leading companies who have implemented principles from this book. As Manager of Flexible Manufacturing at Intel's Systems Group, he developed manufacturing strategies, designed flexible tooling, and initiated their successful programs for standardization and DFM.

For seven years, his own company, Anderson Automation, Inc., built special production equipment for companies such as IBM and Optical Coating Labs and generated production equipment design studies for SRI International, Clorox Manufacturing, and two divisions of FMC. He has been issued four patents and is working on more.

Dr. Anderson is a Fellow of ASME (American Society of Mechanical Engineers) and has been certified for 10 years as a Certified Management Consultant (CMC) by the Institute of Management Consultants. He holds professional engineering (P.E.) registrations in Mechanical, Industrial, and Manufacturing Engineering and a Doctorate in Mechanical Engineering from the University of California at Berkeley.

Dr. Anderson can be reached at [phone] or [e-mail].

Product Details

• Hardcover: 512 pages
• Publisher: C I M Pr (July 1, 2008)
• Language: English
• ISBN-10: 1878072307
• ISBN-13: 978-1878072306
• Product Dimensions: 8.9 x 6.1 x 1.6 inches
• Shipping Weight: 2.3 pounds (View shipping rates and policies)
• Average Customer Review: 4.1 out of 5 stars  See all reviews (7 customer reviews)
• Amazon Best Sellers Rank: #367,996 in Books (See Top 100 in Books)

Customer Reviews

Most Helpful Customer Reviews

2 of 2 people found the following review helpful:

5.0 out of 5 stars Build-to-Order & Mass Customization, December 29, 2006

By 

James William Martin "Author" (Boston/ Providence) - See all my reviews

Amazon Verified Purchase

This review is from: Build-to-Order & Mass Customization; The Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory (Hardcover)

Mass customization is a goal of almost every manufacturing organization. It is especially difficult to find in one book the essential tools, methods and concepts which will enable an organization to migrate towards a build-to-order or mass customization system. This book provide practical advice regarding product rationalization, design standardization and other tools, methods and concepts which any organization will find immediately useful in expanding its operational flexibility.

2 of 2 people found the following review helpful:

4.0 out of 5 stars Interesting and useful, February 28, 2006

By 

David Novellon Latre (Spain) - See all my reviews
(REAL NAME)   

This review is from: Build-to-Order & Mass Customization; The Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory (Hardcover)

If you are a manager in something related with production, or just interested in Mass Customization, this book is for you. It brings a new aproach to the usual concepts, and may change your point of view about supply chain management or product design.

I really consider it's worth the trouble reading it

4 of 5 people found the following review helpful:

5.0 out of 5 stars Feedback from a mass customization implementor, June 30, 2004

By 

David Gardner "Gardner & Associates Consulting" (United States) - See all my reviews
(REAL NAME)   

This review is from: Build-to-Order & Mass Customization; The Ultimate Supply Chain Management and Lean Manufacturing Strategy for Low-Cost On-Demand Production without Forecasts or Inventory (Hardcover)

This is a very practical, "must-have" book--in contrast to the earlier "wouldn't-it-be-nice" writings that focus on the mass customization or build-to-order paradigm shift. This excellent book shows how to implement mass customization including the prerequisites, like product line rationalization and standardization, that greatly simplify supply chains and operations and thus make it easier to implement mass customization. The chapter on outsourcing is the most thorough treatment out there -- reading this would save many companies from costly mistakes that inhibit flexibility and thwart mass customization.

Five chapters on supply chain management show how to simplify supply chains to the point where parts and materials can be pulled into production on-demand to support on-demand production. Intricate perspective plant drawings show the flow of parts and information for the mass customization of fabricated or electronic products. The two chapters on total cost and how to quantify it are something all companies need, especially mass customizers. The book concludes with a chapter on implementation and another that presents the business case for mass customization.

The 520 page book is comprehensive, but busy executives can get up to speed quickly by reading the executive summary which summarizes the whole book. It is easy to read with hundreds of side-bars which highlight key points. It makes a fantastic reference book with hundreds of headings and a huge index.