Profitability with No Boundaries

Robert E. Fox, Reza M. (Russ) Pirasteh

Description

Authors Pirasteh and Fox know what causes various improvement approaches to fail, and in response provide a new model that combines theory of constraints (TOC), lean, and Six Sigma into a unique program called TLS. This scientifically proven methodology improves results dramatically.
The book is divided into two parts. The first is geared to senior decision makers—those who decide “if” their company should adopt a TLS approach. The second deals with the details of “how” and is directed at those responsible for implementing TLS. Readers who would like more depth on any section of Part I can go directly to the matching chapter in Part II.
If your intention is to learn how to systematically improve quality, process reliability, and throughput while creating a wasteless enterprise, then this book is for you!

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Gestion et management
• risk management
• FMEA
• Economics
• Analyse des modes de défaillance, de leurs effets et de leur criticité

Informations

• Publié par: ASQ Quality Press
• Date de parution: 05 mai 2010
• Nombre de lectures: 0
• EAN13: 9780873893534
• Langue: English
• Poids de l'ouvrage: 5 Mo

Extrait

Profi tability with
No Boundaries
00_FM_pg00i-xvi_Pirasteh_ASQ.indd i 8/31/10 4:00 PMAlso available from ASQ Quality Press:
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The Executive Guide to Understanding and Implementing Lean Six Sigma:
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The Certifi ed Six Sigma Black Belt Handbook, Second Edition
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Six Sigma for the New Millennium: A CSSBB Guidebook, Second Edition
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The Certifi ed Six Sigma Green Belt Handbook
Roderick A. Munro, Matthew J. Maio, Mohamed B. Nawaz, Govindarajan Ramu, and
Daniel J. Zrymiak
5S for Service Organizations and Offi ces: A Lean Look at Improvements
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Lean Kaizen: A Simplifi ed Approach to Process Improvements
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Lean for Service Organizations and Offi ces: A Holistic Approach for Achieving Operational
Excellence and Improvements
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Lean ISO 9001: Adding Spark to your ISO 9001 QMS and Sustainability to Your Lean Efforts
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Root Cause Analysis: Simplifi ed Tools and Techniques, Second Edition
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The Certifi ed Manager of Quality/Organizational Excellence Handbook, Third Edition
Russell T. Westcott, editor
Enabling Excellence: The Seven Elements Essential to Achieving Competitive Advantage
Timothy A. Pine
To request a complimentary catalog of ASQ Quality Press publications,
call 800-248-1946, or visit our Web site at http://www.asq.org/quality-press.
00_FM_pg00i-xvi_Pirasteh_ASQ.indd ii 8/31/10 4:00 PMProfi tability with
No Boundaries
Optimizing TOC, Lean, Six Sigma Results
Focus
Reduce Waste
Contain Variability
Reza (Russ) M. Pirasteh
Robert E. Fox
ASQ Quality Press
Milwaukee, Wisconsin
00_FM_pg00i-xvi_Pirasteh_ASQ.indd iii 8/31/10 4:00 PMAmerican Society for Quality, Quality Press, Milwaukee 53203
© 2011
All rights reserved. Published 2010
Printed in the United States of America
14 13 12 11 10 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
Pirasteh, Reza M., 1956–
Profi tability with no boundaries : optimizing toc and lean-six sigma / Reza M. Pirasteh.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-87389-795-2 (alk. paper)
1. Theory of constraints (Management) 2. Six sigma (Quality control standard) 3. Industrial
productivity. I. Title.
HD69.T46.P57 2010
658.4013—dc22
2010021466
ISBN-13: 978–0-87389-795-2
No part of this book may be reproduced in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Matt Meinholz
Project Editor: Paul O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational, and community
excellence worldwide through learning, quality improvement, and knowledge exchange.
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Printed on acid-free paper

00_FM_pg00i-xvi_Pirasteh_ASQ.indd iv 8/31/10 4:00 PMContents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Part I: Leadership Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1: Productivity, Growth, and Prosperity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HENRY FORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALFRED SLOAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TAIICHI OHNO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TLS—A FOURTH WAVE 17
Chapter 2: Productivity Improvement—A Checkered History . . . . . . . . . . . . . . . . . . . 25
Chapter 3: What Is an Improvement?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HOW TO MEASURE AN IMPROVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
WHY IMPROVEMENTS EFFORTS OFTEN FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 4: Current CPI Favorites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
THEORY OF CONSTRAINTS (TOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
The Five Focusing Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Thinking Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Critical Chain Project Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SIX SIGMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Six Sigma—A Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Six Sigma—A Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Step 1—Defi ne. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Step 2—Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Step 3—Analyze 47
Step 4—Improve 48
Step 5—Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Design For Six Sigma (DFSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Six Sigma—A Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Summary/Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 5: The TLS Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
WHAT IS iTLS™®? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
How Does iTLS™® Work?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
v
00_FM_pg00i-xvi_Pirasteh_ASQ.indd v 8/31/10 4:00 PMvi Profi tability with No Boundaries
WHAT IS UNIQUE ABOUT ITLS™®? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HOW SHOULD ITLS™® BE APPLIED? WHAT IS THE
SEQUENCE OF EVENTS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 6: Results: Has a More Global Focus Worked? . . . . . . . . . . . . . . . . . . . . . . . . . 61
INITIAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
WHICH METHODOLOGY WAS MOST EFFECTIVE?. . . . . . . . . . . . . . . . . . . . . 62
Chapter 7: Throughput Operating Strategies (TOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
A NETWORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
V NETW69
T NETWORKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
I NETWORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chapter 8: Management Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FOCUSING IMPROVEMENT EFFORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
MOTIVATING THE DESIRED BEHAVIORS AND BUILDING TRUST. . . . . . . . . . 77
THE MISSING LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Chapter 9: Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Part II: Practitioner’s Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Chapter 1: Productivity Growth and Prosperity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
FORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SLOAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Product Pricing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Investment Decisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Make vs. Buy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
OHNO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A FOURTH WAVE—iTLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .