(Productivity Press: New York) -- Although it is a given that most lean companies adopt methods to standardize cyclical activities, they often fail to apply the same rigor to noncyclical work, believing that it cannot be measured. Standardized Work for Noncyclical Processes (Productivity Press, 2010), by Joseph Niederstadt cuts to the core of this mistaken belief and shows you how to measure nonrepeating job processes and eliminate waste associated with noncyclical activities.
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Taking a hands-on approach reflective of his time as an operator on the line, Niederstadt lays out the methods he has instituted successfully in more than 30 factories around the world. He defines and details a proven process for building consistent quality products at reduced costs, and includes coverage of activities involving multiple-machine job setters, maintenance, stockers, and quality auditors. When implemented correctly this method can help increase utilization to 85 percent through intelligent data collection.
Presenting a wealth of process charts and visual reference tools, the book illustrates how to:
• Identify abnormalities and waste
• Foster teamwork and knowledge sharing
• Promote a safe work environment
• Ensure a balanced workload
• Establish a baseline for continuous improvements
Throughout the book, the author references blank forms and offers numerous examples of what the forms should look like when populated with the proper data. The CD that accompanies the book includes e-versions of all the forms, as well as color versions of images found in the text.
Niederstadt, like many others in the lean area, started work in a General Motors Corp. factory with the goal of making money and providing benefits for his family yet to come. He never realized that it was the beginning of a career in manufacturing that would span beyond 30 years. Later he held positions at Chevrolet Motor Division and Delphi as an assembly line operator and a water spider on an assembly line; he worked supervising machining, assembly, after-market operations, quality control, production control and logistics, labor relations, a lean core team, supplier development, and international assignments. During this progression Niederstadt has never forgotten his roots as an operator and has always striven to make the work environment better for the operator. He has been taught by several senseis from Toyota and some of the best lean people at GM and Delphi.
Niederstadt has worked in the United States, Canada, Mexico, Brazil, Taiwan, India, Korea, China, and Thailand applying the system approach in this book. Most recently he was the director of lean applications of the Asia-Pacific Region for a global corporation. He is currently an independent consultant.
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