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Fundamentals of Flow Manufacturing [Paperback]

Gerard Leone (Author), Richard D. Rahn (Author)
4.0 out of 5 stars  See all reviews (1 customer review)


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Book Description

July 2002
In spite of its widespread and growing acceptance around the world, a clear explanation of the methods of flow manufacturing has been lacking. In Fundamentals of Flow Manufacturing, flow veterans Gerard Leone and Richard D. Rahn fill this void with a step-by-step exposition of flow manufacturing strategies. Presenting the implementation process with entertaining and easy-to-understand examples, case histories and war stories, Leone and Rahn make it possible for both manufacturing and non-manufacturing professionals to understand how this strategy applies to them. The benefits include fast response time to customers, error-free processes, high quality and productivity, and the ability to compete in today’s global economy.

Leone and Rahn are experts in flow manufacturing, and as trainers and consultants they have implemented flow in some of the world’s largest companies, including GE, Boeing, Kodak, Applied Materials and Emerson Electric. Mr. Rahn is also the author of Advanced Flow Manufacturing, published in 2001.


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Editorial Reviews

About the Author

Gerard Leone, MS IE - MBA

During Mr. Leone’s nearly 20-year career in manufacturing management and consulting he had the opportunity to work with a broad range of manufacturing enterprises. Originally from Buenos Aires, Argentina, his multilingual skills have been a very valuable tool in spreading the word of Flow Manufacturing around the world. He taught statistics at the University of Buenos Aires and Production Management at Colorado State University, his two Alma Maters.

A widely recognized leader in the fields of productivity improvement and manufacturing systems, Gerard has instructed and implemented Flow Processing techniques in the factory and in the office with companies like GN ReSound, The New Piper Aircraft, Whirlpool, Mobile Tool International, Lucent Technologies, Beltone, AVAYA, Thermo King and Boeing, to name a few.

Today, Mr. Leone is a Senior partner with the Business Process Consulting Group, a consulting firm dedicated to training and consulting in Flow Processing for the factory and the office, based in Littleton, Colorado.

Richard D. Rahn, MBA, CPIM

Richard D. Rahn is the president of FlowAlliance a Flow Manufacturing consulting, publishing and software tools firm headquartered in Boulder, Colorado. Formerly a vice-president with both the Kiran Consulting Group and the John Costanza Institute, Richard is a recognized leader in training and implementation of Flow Manufacturing. He has lead over 30 successful implementation programs in the US, Canada, Europe and Mexico, and has trained over 3,000 manufacturing professionals in Flow Manufacturing techniques. He has introduced Flow Manufacturing to some of the world's largest companies, including General Motors, Johnson & Johnson, John Deere, Kodak and Emerson Electric.

FlowAlliance is a pioneer in the development of lean tools for Flow Manufacturing, including the use of computer simulation modeling and Advanced Planning methodologies. This approach is presented in Richard’s first book, Advanced Flow Manufacturing.

Richard was raised in Manila and Mexico City, and teaches and consults in Spanish and English. He graduated Cum Laude from Middlebury College, Middlebury, Vermont and received his MBA from the University of Colorado. He has 14 years of manufacturing and management experience with Ball Aerospace in Boulder, Colorado and Storage Technology Corporation in Louisville, Colorado. Flow Manufacturing has been his specialty for the past 12 years.


Product Details

  • Paperback: 231 pages
  • Publisher: Flow Pub (July 2002)
  • Language: English
  • ISBN-10: 0971303185
  • ISBN-13: 978-0971303188
  • Product Dimensions: 8.9 x 8 x 0.7 inches
  • Shipping Weight: 1.4 pounds
  • Average Customer Review: 4.0 out of 5 stars  See all reviews (1 customer review)
  • Amazon Best Sellers Rank: #1,229,103 in Books (See Top 100 in Books)

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4 of 4 people found the following review helpful:
4.0 out of 5 stars Detailed and practical guide to Flow., April 16, 2004
By 
Dave Piasecki (Kenosha, WI United States) - See all my reviews
(REAL NAME)   
This review is from: Fundamentals of Flow Manufacturing (Paperback)
Though the title states "fundamentals", I think this book goes beyond that in its treatment of flow. I don't like "theory" books so I was very pleased with the practical approach taken by the authors. Most lean/JIT books cover flow, but rarely in enough detail; Fundamentals of Flow Manufacturing does a good job of balancing adequate detail without overloading the reader. I also have to complement the authors on sticking to the topic and not getting sidetracked into other lean topics.

Of particular interest are the detailed calculations associated with setting up flow lines and kanbans. I also appreciated the discussion of the implications of manufacturing software and flow. This book is very well organized and a moderately quick read.

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Inside This Book (learn more)
First Sentence:
The way that work is done is being transformed for both manufacturing and service-based industries. Read the first page
Key Phrases - Statistically Improbable Phrases (SIPs): (learn more)
standard work definition, graphic work instructions, implementing flow manufacturing, process flow map, work content times, flow manufacturing environment, flow manufacturing methods, power tools factory, takt time, workstation definition, sequential workstations, kanban quantities, supermarket locations, flow manufacturer, single piece flow, throughput volume, resource calculations, flow factory, manufacturing implementation, kanban signals, stream mapping, flow environment, inventory transactions, pull signal, kanban system
Key Phrases - Capitalized Phrases (CAPs): (learn more)
Chain Saw, Orbital Sander, United States, Bill of Material, Circular Saw, Bills of Material, Order Entry, Toyota Production System, Forecasted Daily Usage, Wiring Harness Assy, World War, Edwards Deming, Grind Motor Assy, Mandrel Assy Final Assy, Order Staging, Safety Stock Factor
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