Reorganizing the Factory: Competing Through Cellular Manufacturing

Winner of the 2003 Shingo Prize!Reorganizing work processes into cells has helped many organizations streamline operations, shorten lead times, increase quality, and lower costs. Cellular manufacturing is a powerful concept that is simple to understand; however, its ultimate success depends on decid [...]
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Winner of the 2003 Shingo Prize!Reorganizing work processes into cells has helped many organizations streamline operations, shorten lead times, increase quality, and lower costs. Cellular manufacturing is a powerful concept that is simple to understand; however, its ultimate success depends on deciding where cells fit into your organization, and then applying the know-how to design, implement and operate them.Reorganizing the Factory presents a thoroughly researched and comprehensive "life cycle" approach to competing through cellular work organizations. It takes you from the basic cell concept and its benefits through the process of justifying, designing, implementing, operating, and improving this new type of work organization in offices and on the factory floor.The book discusses many important technical dimensions, such as factory analysis, cell design, planning and control systems, and principles for lead time and inventory reduction. However, unique to the literature, it also covers in depth the numerous managerial issues that accompany organizing work into cells.In most implementations, performance measurement, compensation, education and training, employee involvement, and change management are critically important. These issues are often overlooked in the planning process, yet they can occupy more of the implementation time than do the technical aspects of cells. Includes:Why do cells improve lead time, quality, and cost?Planning for cell implementationJustifying the move to cells, strategically and economicallyDesigning efficient manufacturing and office cellsSelecting and training cell employeesCompensation system for cell employeesPerformance and cost measurementPlanning and control of materials and capacityManaging the change to cellsProblems in designing, implementing, and operating cellsImproving and adapting existing cellsStructured frameworks and checklists to help analysis and decision-makingNumerous examples of cells in various industries