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New Manufacturing Challenge: Techniques for Continuous Improvement
 
 
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New Manufacturing Challenge: Techniques for Continuous Improvement [Hardcover]

Kiyoshi Suzaki (Author)
4.6 out of 5 stars  See all reviews (10 customer reviews)

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Book Description

July 22, 1987
As a consultant, Kiyoshi Suzaki has helped scores of Fortune 500 clients improve manufacturing operations and get the job done faster, cheaper, better, and safer. Now, in this detailed "operating manual" -- full of more step-by-step applications than any other book available -- Suzaki spells out new options in production and employee resources that can help American industry regain the cutting edge in price, quality, and delivery of products.

A well-known expert in the field, Suzaki begins with the premise that "if it doesn't add value, it's waste" -- a concept devised by Henry Ford and later used by Toyota. He recaps what Toyota identifies as the seven most prominent forms of waste in factories. Most importantly, he meticulously details steps individuals can take to "simplify, combine, and eliminate operations" -- thereby reducing waste, improving quality, and saving money.

Describing in detail the basic techniques culled from Japanese industrial philosophy and procedure, Suzaki shows how small, family-run businesses and billion-dollar American corporations from a wide range of industries -- automotive, electronics, cosmetics, and even defense contractors -- are meeting the manufacturing challenge today -- demolishing the widely held belief that most American manufacturers have become distribution organizations for products manufactured overseas. In addition, he links his methodology with several successful production systems, from Just-In-Time Production, Total Quality Control, Total Productive Maintenance to Computer Integrated Manufacturing. Throughout this practical handbook, he places emphasis squarely on the shop floor and grounds his approach in easy, yet powerful techniques everybody can understand and implement today.

Illustrated with numerous charts and exhibits, The New Manufacturing Challenge shows how to integrate people and techniques to improve the workplace and, thus, strengthen any company's competitiveness in the global marketplace.


Frequently Bought Together

New Manufacturing Challenge: Techniques for Continuous Improvement + Creating a Lean Culture: Tools to Sustain Lean Conversions, Second Edition + Lean Thinking: Banish Waste and Create Wealth in Your Corporation, Revised and Updated
Price For All Three: $80.51

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Editorial Reviews

From Library Journal

Maintaining world competitiveness has been the clarion call for many industries in the 1980s. For manufacturing companies, improving production efficiency has been the key. This work lays out specific suggestions for improving manufacturing techniques on the shop floor. The chapters, profusely illustrated, treat topics such as quick setup, job rotation, U-shaped production lines, and preventive maintenance. In each, the author uses his diverse experience as an efficiency expert for several leading consulting houses to good advantage. However, the volume lacks a strong philosophical framework and comes off rather like a dry list of helpful hints. Recommended only for production specialists. Gene R. Laczniak, Coll. of Business Administration, Marquette Univ., Milwaukee
Copyright 1987 Reed Business Information, Inc.

Review

Tom Peters Co-author of In Search of Excellence and A Passion for Excellence Continuous improvement, with everyone involved, must become the American norm -- or else. We must shed 150 years of wrong-headed thinking. Kiyoshi Suzaki makes an important contribution to our doing just that.

Lewis E. Platt Senior Vice President, Hewlett-Packard Company It's packed with examples which reinforce techniques for continuous improvement and stir the reader to action. It also helps us develop a common understanding of how to restore our competitive edge.

John L. Warne Former President and COO, Omark Industries An excellent resource for operating managers who want to bring their manufacturing up to world class.

Leonard A. Harvey Executive Vice President, Borg-Warner Corporation ...this book cuts through a lot of the mystique in modern manufacturing...it demonstrates, in a concise manner, the perceptions needed to make today's factory competitive.

Brian Kelley Plant Manager, Cummins Engine Company Suzaki's book is a practitioner's book -- not another theory book.

Leonard J. Ricard Director-Inventory Management and Methods, General Motors Corporation This book is filled with practical techniques for improving quality and productivity together with scores of examples of the application of those techniques. It is a valuable handbook for all who must meet today's competitive manufacturing challenges.

Shoichi Saba Chairman and CEO, Toshiba Corporation Suzaki describes the core of Japanese manufacturing techniques...this simple yet very insightful work should be shared by business leaders and practitioners around the world.

J. Richard Iverson President and CEO, American Electronics Association Mr. Suzaki develops basic manufacturing approaches that will truly challenge the perceptive manager.

Robert W. Hall Professor of Operations Management, Indiana University School of Business Readers unfamiliar with the new production will find the book an easily read explanation of Japanese 'techniques...Experienced readers will find a great blend of current Japanese and American thinking.

Kenneth L. Thorpe Executive Vice President, Society of Manufacturing Engineers Every manufacturing manager and top executive should read this book to learn how they can gain an advantage over their competition through discipline, involvement and common sense.

Product Details

  • Hardcover: 255 pages
  • Publisher: Free Press (July 22, 1987)
  • Language: English
  • ISBN-10: 0029320402
  • ISBN-13: 978-0029320402
  • Product Dimensions: 9.6 x 6.3 x 1 inches
  • Shipping Weight: 1 pounds (View shipping rates and policies)
  • Average Customer Review: 4.6 out of 5 stars  See all reviews (10 customer reviews)
  • Amazon Best Sellers Rank: #100,323 in Books (See Top 100 in Books)

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20 of 20 people found the following review helpful:
5.0 out of 5 stars Great book, balances concepts and details very nicely, March 8, 1999
This review is from: New Manufacturing Challenge: Techniques for Continuous Improvement (Hardcover)
Anybody interested in reducing manufacturing cycle times should read this book (among others) to get some great examples of what can be done. It has many very specific examples and strong fundamental concepts. Very easy to read as well.
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10 of 10 people found the following review helpful:
5.0 out of 5 stars 5 stars plus, May 17, 2001
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J. head (littlteton, nh USA) - See all my reviews
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This review is from: New Manufacturing Challenge: Techniques for Continuous Improvement (Hardcover)
This is THE book for hands-on actual implementation of lean production techniques. This book answers the difficult problems accompaning implementation of the Toyota Production System. It is written in an easily understood straight-forward style. In my opinion this is the best book on boosting shopfloor efficiency. It does not shy away from discussing the problem areas. The author proves he has "been there and done it". An example is the Kanban system usually described in most books as a sytem where cards control the shop floor work flow. This book describes in detail various Kanban systems to handle the situations where the work flow is interrupted by processes requiring outside vendors or where an operation such as heat treating will slow the process. I rated this book five stars because it discusses real problems and solutions.
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10 of 10 people found the following review helpful:
5.0 out of 5 stars One of the Best on the Toyota Production Systems, March 10, 1998
By A Customer
This review is from: New Manufacturing Challenge: Techniques for Continuous Improvement (Hardcover)
The book covers the basic concepts often associated with Toyota Production System. Suzaki takes it one step farther by adding his own creativity and experiences as a lean manufacturing consultant. This is one of the best and most inspirational books I have read on the subject of continuous improvements. ~ Rhett A. Cooper
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Inside This Book (learn more)
First Sentence:
Unfortunately there is too much waste in our work environment. Read the first page
Key Phrases - Statistically Improbable Phrases (SIPs): (learn more)
line stop concept, work combination charts, multiprocess handling, production control board, triple handling, kanban concept, kanban post, signal kanban, andon light, mixed loading, setup time reduction, kanban cards, internal setup, production cards, production lead time, automotive parts manufacturer, machine trouble, foolproof mechanisms, mixed production, upstream process, production lot size, final assembly line, move cards, pitch marks, bolt tightening
Key Phrases - Capitalized Phrases (CAPs): (learn more)
West Coast, United States, Silicon Valley, Taiichi Ohno, Visual Control Applied, Grinding Operation, Henry Ford, Japanese Manufacturing Techniques, Journal of Business Strategy, Phase Probability of Machine Failure, Their Importance, Top View
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