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Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement
 
 
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Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement [Hardcover]

James Ignizio (Author)
5.0 out of 5 stars  See all reviews (5 customer reviews)

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Book Description

July 17, 2009

TQM, Reengineering, Theory of Constraints, JIT, Six Sigma, Lean Manufacturing . . .

These are just some of the methods that, over the past five decades, have promised to transform any manufacturing firm into a lean, mean, moneymaking machine. While each incorporates certain fundamental truths, strengths, and benefits, they are not panaceas. Nor do they necessarily provide much-needed insight into the science that underlies factory performance.

James Ignizio, Ph.D., an internationally recognized performance optimization expert, believes that only a balanced approach will provide the significant and sustainable improvement required of firms who will survive and prosper in the twenty-first century.

In this breakthrough guide, Dr. Ignizio picks up where such concepts as Six Sigma and Lean Manufacturing leave off to provide you with a holistic, three-dimensional approach to mastering the art and science of manufacturing.

Focusing on the three primary enemies of factory performance—complexity, variability, and lackluster leadership—Optimizing Factory Performance cuts to the heart of the problem of less-than-world-class performance and demonstrates how those enemies manifest themselves in companies across manufacturing sectors. Ignizio also explores the insidious effect company politics and flagging commitment to manufacturing performance have on competitiveness.

Emphasizing the all-important, often overlooked third dimension of manufacturing—factory protocols—Ignizio describes the types of strategicand tactical changes to physical plant and operating procedures any company can make to achieve performance improvements. In addition, he arms you with powerful, original metrics for measuring and comparing factory performance, as well as a set of interactive simulation models, available online at www.mhprofessional.com/ignizio.

Running throughout the book is an often amusing, always instructive account of the fictional high-tech firm, Muddle, Inc., which helps support the concepts discussed in the real world of manufacturing, while reinforcing key lessons learned.

Read Optimizing Factory Performance and find out how to transform your organization into the kind of fast, agile manufacturer that delivers the right products to the right customers at the right time— every time.


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Editorial Reviews

From the Back Cover

Boost factory performance and transform your company into a world-class competitor

You can dramatically improve factory performance, decrease cycle time, increase capacity, and cut costs, while expanding your profits and market share. You won’t need to invest in new equipment and technologies, make sweeping personnel cuts, or relocate your facilities to far-flung locales around the globe. Best of all, these improvements will be sustainable.

Sound too good to be true? You won’t think so once you’ve read Optimizing Factory Performance.

Unlike TQM, Six Sigma, Lean Manufacturing, and similar “remedies,” which offer only partial solutions to the problem of manufacturing inefficiency, the methodology outlined in this book is firmly rooted in the real world of manufacturing and based on sound science. Dr. James Ignizio offers a balanced, three-dimensional approach to understanding, measuring, and conquering the three enemies of manufacturing: complexity, variability, and poor leadership. Armed with simple, easy-to-use metrics, interactive factory simulation models, and other original tools, you will

  • Cut cycle times
  • Increase capacity
  • Reduce variability in outs and lead times
  • Decluster starts and maintenance events
  • Root out performance-killing company politics and turf battles
  • Create a culture of continual performance improvement

About the Author

James P. Ignizio, Ph.D., is founder and principal of FactoryAnalyst.com, a consulting practice with clients on four continents, including those in the semiconductor and solar cell manufacturing sectors. Dr. Ignizio is the author of nine books and over 350 technical papers, including more than 150 articles in peer-reviewed professional journals. He is a Fellow of the Institute of Industrial Engineering, a Fellow of the British Operational Research Society, and a Fellow of the World Academy of Productivity Science. Over the past 30 years, he has presented short courses and seminars on manufacturing, operations research, and industrial engineering to thousands of professionals in industry and government.

Product Details

  • Hardcover: 400 pages
  • Publisher: McGraw-Hill; 1 edition (July 17, 2009)
  • Language: English
  • ISBN-10: 0071632859
  • ISBN-13: 978-0071632850
  • Product Dimensions: 9.1 x 5.9 x 1.3 inches
  • Shipping Weight: 1.5 pounds (View shipping rates and policies)
  • Average Customer Review: 5.0 out of 5 stars  See all reviews (5 customer reviews)
  • Amazon Best Sellers Rank: #760,752 in Books (See Top 100 in Books)

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3 of 3 people found the following review helpful:
5.0 out of 5 stars A must read for factory managers and engineers, July 24, 2009
This review is from: Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement (Hardcover)
Professor James Ignizio's book (Optimizing Factory Performance) may receive mixed reviews from its readers. Those who might insist that such methods as Lean Manufacturing, Six Sigma, Theory of Constraints, or Reengineering are infallible, have an unlimited scope, and may be applied in isolation (e.g., with little regard to the politics and culture of the organization and/or in lieu of an appreciation of the scientific foundation of production line performance) may find the book unnerving if not controversial. As Ignizio points out, while such methods as Lean, Six Sigma, and ToC provide a means to achieve significant improvement in factory performance, they are not a panacea and they represent but one part of the achievement of any sustainable results. Such methods must be applied to the right problem, in the right manner, by those with the right training - and having an appreciation of both their scope and limitations.

Those who seek a practical, yet scientifically-based means to improve factory (or supply chain) performance will, on the other hand, likely be delighted. As Professor Bill Biles (University of Louisville) cites in his Foreword to Ignizio's book, Optimizing Factory Performance "provides a major step forward in establishing a science of manufacturing systems." Biles goes on to say that "[Ignizio] advances the science of manufacturing systems in ways no other author has even attempted." Having read the book, and as someone aware of the significant results of its pragmatic approach, I could not agree more.

The first part of the book (Chapters 1 through 8) provides the foundation for the understanding of the operation of production lines and the causes of degraded performance. Ignizio insists that it is imperative to isolate and remove the causes of problems - rather than simply attempt to sooth their symptoms. He provides a number of original approaches in support of this goal. Of particular importance is his introduction of factory performance metrics that provide a means to objectively evaluate and compare factory performance - and normalized to account for changes in factory loading as well as being appropriate for non-traditional factories (e.g., reentrant production lines such as employed in semiconductor fabs). Chapter 2 of the book, an accounting of the history of manufacturing, is in itself worth the price of the text.

The second half of the book (Chapters 9 through 15) covers methods to deal with the three obstacles to factory performance (i.e., complexity, variability, and lackluster leadership). These methods are accompanied by illustrative examples. Whether the reader is a college student, university professor, factory engineer, or a manager within a factory setting, the book provides an understanding of production lines that has not been seen heretofore. Ignizio's book should, in particular, be required reading for the managers who have a serious interest in understanding and dealing with the actual running of a real world factory.
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2 of 2 people found the following review helpful:
5.0 out of 5 stars Strongly recommend this book, July 24, 2009
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This review is from: Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement (Hardcover)
As someone who has witnessed, first-hand, the successful results of the implementation of the basic approach and many of the concepts covered in Ignizio's book, I would strongly encourage its adoption in both industry and academia. An approach that couples the politics, art, and science of manufacturing is unique and, for the most part, missing from either university courses or industrial training courses. Ignizio's book rectifies that omission.

Ignizio provides a clear and comprehensive overview of production lines and the causes of performance degradation. He avoids the hyperbole found in some books and, instead, focuses on the means necessary to describe, measure, and provide significant and sustainable factory performance. Clearly Ignizio has experience working in a factory and providing him an appreciation of what it takes to run an actual production line.

Accompanying each chapter of the book is an ongoing story of a fictional manufacturing firm, the Muddle Corporation. This novelette alone is worth the price of the book. Anyone who has worked in any organization will recognize the types of characters and situations introduced in these stories. Each tale serves to reinforce the ideas in the main body of the text and to indicate the crucial impact of a firm's culture and politics on the success or failure of any type of effort to improve factory performance. Frankly, the book deserves six stars.
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5.0 out of 5 stars Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement (Hardcover), September 15, 2010
This review is from: Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement (Hardcover)
Prof. James Ignizio presents in this book a substantive, objective, and scientific basis to understand factory performance and operation. The author cumulative experience on manufacturing management, besides his academic background, allows him to present this excellent book for students in Engineering, science and business programs. The book shows the importance of real-world problems to understand factory dynamics and how to tackle with these problems by developing proper manufacturing strategies and tactics. Congratulations on a great book.
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