Manufacturing at Warp Speed: Optimizing Supply Chain Financial Performance (St. Lucie Press/Apics Series on Constraints Management,)

Manufacturing systems don't exist in a vacuum, isolated from the rest of the company, but they are often managed that way. A truly effective, highly competitive manufacturing company integrates its manufacturing, marketing, sales, purchasing, and financial functions into a well-coordinated whole. Manufacturing at Warp Speed: Optimizing Supply Chain Financial Performance explains in detail how to coordinate all these functions to maximize sales revenue while controlling inventory and overhead costs. Ultimately, the effects of applying the new Simplified-Drum-Buffer-Rope (DBR II) introduced by the authors include dramatically faster manufacturing cycle times, shorter order-to-delivery lead times, higher on-time delivery reliability, and better customer satisfaction.The book gives you everything a typical production professional needs to implement this new DBR approach. A supplemental feature - the Management Interactive Case Study Simulator (MICSS) - is included with the book. This CD-ROM sets up a virtual company where you can test and practice the processes you learn in the book before implementing them in your organization. The book and software together constitute the complete package for learning how to streamline manufacturing operations. The first book available on second generation Drum-Buffer-Rope, Manufacturing at Warp Speed: Optimizing Supply Chain Financial Performance describes the simplest, most efficient methods for reducing manufacturing cycle time and increasing the speed of manufacturing yet devised. Fully illustrated, with numerous examples, case studies, and manufacturing scenarios, the book is so easy to read that even the novice can understand it. Correct use of this new method practically assures your company has the competitive advantage. Case Study: Reliable Manufacturing, Inc. -- What Are Our Requirements For A Solution? -- Part I Managing System Constraints -- 1 Systems Thinking: The Foundation 13 -- System Vs. Process -- Work Flow Vs. The Organization Chart -- Suboptimization -- Local Vs. System Optima -- Systems As Chains -- Manufacturing Chain -- Expanded Manufacturing Chain -- Eternal Constraint -- Importance Of Knowing What The System Constraint Is -- 2 Principles And Tools Of The Theory Of Constraints 23 -- Constraint Management Assumption -- Airplane Analogy -- Nero Effect -- Theory Of Constraints Approach To System Management -- Five Focusing Steps -- Toc Perspective: A Summary -- Ramifications Of The Five Focusing Steps -- 3 Assessing System Success 39 -- Evaluating Operating Decisions: The Traditional Approach -- Evaluating Operating Decisions: The Toc Approach -- Relation Of T, I, And Oe To Traditional Business Measures Of Merit -- What Should Our Priorities Be? -- T, I, And Oe: An Example -- Throughput (constraint) Accounting -- 4 Constraint Management Tools 49 -- Types Of Constraints -- Constraint Types: Examples -- Logical Thinking Process -- Critical Chain -- Drum-buffer-rope Production Scheduling -- Five Focusing Steps Revisited -- 5 How Work Flows Through A Manufacturing Process 59 -- A Flow -- V Flow -- I Flow -- T Flow -- Various Manufacturing Environments And Their Specific Problems -- Part Ii Traditional Drum-buffer-rope -- 6 Applying Constraints Theory To Manufacturing Operations 73 -- Simple Production Organization -- Injections: Breaking Conflict -- Transfer Batches -- Future Reality Tree: Plant 120 -- Generic Manufacturing Conflict -- 7 Traditional Drum-buffer-rope 99 -- What Dbr Does -- What Dbr Does Not Do -- Some Basic Dbr Principles -- Guidelines For Dbr Shop Floor Planning -- Dbr Basic Concepts -- Control Conflict: Detail Or No Detail? -- Buffers: Traditional Dbr -- Preliminary Actions -- Control Conflict Revisited -- Managing Non-constraints In A Dbr Environment -- 8 Traditional Buffer Management: The Dbr Control Mechanism 123 -- Buffer Concept -- Buffer Management -- Dbr Buffers: Three Zones -- Holes In A Buffer -- How A Hole In A Buffer Appears In The Master Production Schedule -- Dbr Buffer Zones: A Ccr Example -- Three Benefits Of Buffer Management -- How To Realize The Benefits Of Buffer Management -- Identifying An Emerging Constraint: An Example -- 9 Drum-buffer-rope (dbr) And Manufacturing Resource Planning (mrp) 137 -- Mrp Advantages -- Mrp Disadvantages -- Mrp Policies That Can Create Problems -- Overcoming Mrp's Disadvantages -- Mrp Lead Times And Queues -- Establishing The Rope -- Problems In Dbr Implementation Within Mrp Systems -- Dbr-specific Software And Dynamic Buffers -- Part Iii Simplified Drum-buffer-rope -- 10 Simplified Drum-buffer Rope (s-dbr) 149 -- Difficulties In Applying Traditional Dbr -- S-dbr: Simplified, Effective -- S-dbr: Basic Assumptions -- S-dbr: Operating Principles -- S-dbr: A Graphic Depiction -- Implementing Simplified Dbr -- S-dbr Control -- S-dbr Problem Situations -- Traditional Dbr And S-dbr: Which To Use When? -- 11 Controlling Uncertainty And Variation: The S-dbr Approach 175 -- Buffers: A Quick Review -- Definition Of Control -- Objectives Of Red-line Control (buffer Management) -- How Red-line Control Works -- Red-line Control For Raw Materials -- Red-line Control: Limitations -- Planned Load: An Important Control Information Source -- Rough-cut Capacity As A Control Mechanism -- Control In S-dbr: A Summary -- Plant Adv200: An S-dbr Simulation -- 12 Managing Excess Capacity 209 -- Excess Capacity: What Can We Do With It? -- Excess Capacity: Protection From What? -- Dilemma Of Maintaining Excess Capacity -- Excess Capacity Conflict -- Effects Of Various Policies On Actual Production Lead Time -- Excess Capacity: A New Way To Think Abouts It -- Common Reasons Why Excess Capacity Remains Hidden -- Cost Mentality And Excess Capacity -- When Is Excess Too Much? -- How To Prepare For Excess Capacity -- How To Expose Excess Capacity -- 13 Throughput-based Decision Support 225 -- Management's Problem -- Management's Challenge -- Traditional Global Measurements -- Toc Global Measurements -- Link Between Toc And Traditional Global Financial Measurements -- How T, I, And Oe Support Daily Decisions -- Calculating The Financial Impact -- Logic Of Measurements -- How T, I, And Oe Support Daily Decisions: Another Example -- Using T, I, And Oe In Making Daily Decisions -- How To Load The Ccr And Maximize T Without Increasing Oe And I -- Throughput-per-constraint-unit Rule: An Example -- When No Ccr Exists: Decision Rules -- How Do Big Decisions Differ From Small Ones? -- How To Determine [delta]t -- How To Determine [delta]oe And [delta]i -- Toc Decision Rule -- 14 Drum-buffer-rope (dbr) And Enterprise Resource Planning (erp) 245 -- Think E, Manage E: Management In The Erp Era -- Case Study: Smpro, Inc. -- Problems Related To Information At Smpro -- Erp Implementation: Basic Assumptions -- Second Erp Assumption -- Third Erp Assumption -- Why Erp? -- Toc Support In An Erp System -- Supply Chain Management -- Appendix A Dice Game -- Appendix B Management Interactive Case Study Simulator (micss). By Eli Schragenheim, H. William Dettmer. Includes Bibliographical References And Index. System Requirements For Computer Disk: Windows 95, 98, Or Nt4.0; Minimum 640x480 256 Color Display; 12 Megabytes Of Free Disk Space; Minimum 16 Megabytes Of Ram; Recommended 32 Megabytes Of Ram. Manufacturing systems don't exist in a vacuum, isolated from the rest of the company, but they are often managed that way. A truly effective, highly competitive manufacturing company integrates its manufacturing, marketing, sales, purchasing, and financial functions into a well-coordinated whole. Manufacturing at Warp Speed: Optimizing Supply Chain Financial Performance explains in detail how to coordinate all these functions to maximize sales revenue while controlling inventory and overhead costs. Ultimately, the effects of applying the new Simplified-Drum-Buffer-Rope (DBR II) introduced by the authors include dramatically faster manufacturing cycle times, shorter order-to-delivery lead times, higher on-time delivery reliability, and better customer satisfaction. The book gives you everything a typical production professional needs to implement this new DBR approach. A supplemental feature - the Management Interactive Case Study Simulator (MICSS) - is included with the book. Available for download via the CRC Press website, the simulator sets up a virtual company where you can test and practice the processes you learn in the book before implementing them in your organization. The book and software together constitute the complete package for learning how to streamline manufacturing operations. The first book available on second generation Drum-Buffer-Rope, Manufacturing at Warp Speed: Optimizing Supply Chain Financial Performance describes the simplest, most efficient methods for reducing manufacturing cycle time and increasing the speed of manufacturing yet devised. Fully illustrated, with numerous examples, case studies, and manufacturing scenarios, the book is so easy to read that even the novice can understand it. Correct use of this new method practically assures that your company has the competitive advantage. Front Cover......Page 1 Contents......Page 8 List of Figures......Page 14 Preface......Page 20 The Authors......Page 26 About APICS......Page 28 Introduction......Page 30 1. Systems Thinking: The Foundation......Page 42 2. Principles and Tools of the Theory of Constraints......Page 52 3. Assessing System Success......Page 68 4. Constraint Management Tools......Page 78 5. How Work Flows through a Manufacturing Process......Page 88 6. Applying Constraints Theory to Manufacturing Operations......Page 102 7. Traditional Drum-Buffer-Rope......Page 128 8. Traditional Buffer Management: The DBR Control Mechanism......Page 152 9. Drum-Buffer-Rope (DBR) and Manufacturing Resource Planning (MRP)......Page 166 10. Simplified Drum-Buffer-Rope (S-DBR)......Page 178 11. Controlling Uncertainty and Variation: The S-DBR Approach......Page 204 12. Managing Excess Capacity......Page 238 13. Throughput-Based Decision Support......Page 254 14. Drum-Buffer-Rope (DBR) and Enterprise Resource Planning (ERP)......Page 274 Appendix A: The Dice Game......Page 292 Appendix B: The Management Interactive Case Study Simulator (MICSS)......Page 306 Appendix C: Plant 120......Page 340 Appendix D: The ADV200 Company......Page 350 Bibliography......Page 360 Index......Page 362 Describes the simplest, most efficient methods for reducing manufacturing cycle time and increasing speed. Fully illustrated and with numerous examples, case studies, and manufacturing scenarios, this title includes Management Interactive Case Study Simulator (MICSS) CD-ROM that sets up a virtual company to test the processes covered in the book.