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Reorganizing the factory : competing through cellular manufacturing / Nancy Hyer and Urban Wemmerlov

Main Author Hyer, Nancy Coauthor Wemmerlov, Urban Country Estados Unidos. Publication New York : Productivity Press, cop. 2002 Description XIV, 770 p. : il. ; 27 cm ISBN 1-56327-228-8 CDU 658.5
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Monografia Biblioteca da UMinho no Campus de Azurém
BPG2 658.5 - H Available 366031
Monografia Biblioteca da UMinho no Campus de Azurém
BPG 658.5 - H Available 378353

Mestrado Integrado em Engenharia e Gestão Industrial Organização de Sistemas de Produção I 1º semestre

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Enhanced descriptions from Syndetics:

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.


Why do cells improve lead time, quality, and cost? Planning for cell implementation Justifying the move to cells, strategically and economically Designing efficient manufacturing and office cells Selecting and training cell employees Compensation system for cell employees Performance and cost measurement Planning and control of materials and capacity Managing the change to cells Problems in designing, implementing, and operating cells Improving and adapting existing cells Structured frameworks and checklists to help analysis and decision-making Numerous examples of cells in various industries

Table of contents provided by Syndetics

  • Preface (p. xi)
  • Acknowledgments (p. xiii)
  • Section 1 Cellular Manufacturing--The Basics
  • Chapter 1 Competing through Cellular Manufacturing (p. 3)
  • Cellular Manufacturing--A Platform for Improvement (p. 4)
  • The Hard and Soft Sides of Cell Implementation (p. 7)
  • Change Seeks Company (p. 13)
  • The Organization of this Book (p. 13)
  • Chapter 2 A Closer Look at Cells: What They Are and the Forms They Take (p. 17)
  • Formal Definitions of Cellular Manufacturing (p. 17)
  • Four Perspectives on Cells (p. 22)
  • Related Types of Production Units (p. 26)
  • Operational Characteristics of Cells (p. 30)
  • The Relationship of Cellular Manufacturing to Other Organizational Principles (p. 37)
  • Chapter 3 Why Cells Improve Performance (p. 45)
  • Point of Departure for Performance Improvements (p. 45)
  • The Sources of Cell Benefits (p. 48)
  • Potential Disadvantages of Cells (p. 60)
  • Determining the Suitability of Cells (p. 63)
  • Section 2 Adopting and Designing Cells
  • Chapter 4 The Planning and Implementation of Cellular Manufacturing Systems (p. 71)
  • The Planning and Implementation Process at a Glance (p. 71)
  • A 13-Step Blueprint for Your Planning Process--The Details (p. 74)
  • Chapter 5 Factory Planning (p. 95)
  • An Overview of Factory Planning (p. 95)
  • Confirming the Course (p. 99)
  • Understanding the Current Situation (p. 100)
  • Identifying Opportunities for Product Focus (p. 112)
  • Identifying Opportunities for Cells (p. 116)
  • Issues in Cell Design (p. 131)
  • Designing a New Factory Layout (p. 137)
  • Modifying the Infrastructure (p. 143)
  • Chapter 6 Detailed Planning--One Cell at a Time (p. 147)
  • Project Organization (p. 147)
  • Which Cell First? (p. 148)
  • Detailed Cell Planning--An Overview (p. 151)
  • Planning Block 1 Cell Formation and Dimensioning (p. 151)
  • Planning Block 2 Management Systems (p. 156)
  • Planning Block 3 Employee, Layout, and Start-Up Issues (p. 157)
  • Cell Dimensioning Revisited (p. 167)
  • Dilemmas in Cell Design and Layout (p. 172)
  • Chapter 7 Understanding Cell Performance Using Modeling (p. 181)
  • Models and Cell Design (p. 181)
  • What Is Manufacturing Lead Time? (p. 182)
  • Elementary Queuing Theory (p. 185)
  • Reducing Manufacturing Lead Time (p. 189)
  • Special Problems in Designing and Operating Cells (p. 193)
  • Queuing and Simulation Models--An Overview (p. 208)
  • The Value of Models and Modeling (p. 215)
  • Chapter 8 Determining the Economic Value of Cells (p. 221)
  • Strategic versus Economic Justifications (p. 222)
  • How to Cost-Justify Cells (p. 224)
  • Estimating the Costs and Benefits of Cellular Manufacturing (p. 226)
  • Discount Rates and Tax Considerations (p. 232)
  • Tangible and Intangible Costs and Benefits (p. 236)
  • Justifying Cells "After the Fact" (p. 238)
  • Some Practical Issues in Justifications (p. 240)
  • Section 3 Designing the Cell System Infrastructure
  • Chapter 9 Performance Measurement for Cells (p. 249)
  • What Is a Performance Measurement System? (p. 250)
  • How to Generate Performance Measures (p. 253)
  • How to Evaluate and Present Performance Measures (p. 257)
  • The Process Performance Measurement Matrix (p. 266)
  • Measuring the Performance of Cells at Turner Products (p. 273)
  • Chapter 10 Cost Accounting and Cellular Manufacturing (p. 281)
  • Standard Costing Systems and Process Improvement--Are They Compatible? (p. 282)
  • How to Modify Your Costing System for Cellular Manufacturing (p. 291)
  • A "New" Cost Accounting System for Cells (p. 307)
  • Chapter 11 Manufacturing Planning and Control Systems for Cells (p. 311)
  • An Overview of Changes to MPC Practices Driven by Cell Adoption (p. 312)
  • MRP/ERP Systems (p. 313)
  • MPC Modifications Driven by Cells--Product Structures and Planning Horizon (p. 314)
  • MPC Modifications Driven by Cells--Capacity Management (p. 318)
  • MPC Modifications Driven by Cells--The Shop Floor Control System (p. 323)
  • MPC Modifications Driven by Cells--Controlling Material Flow through Pull Systems (p. 329)
  • Planning and Controlling Supplier Orders (p. 347)
  • MPC Modifications Driven by Cells--Lot-Sizing and Transfer Batching (p. 349)
  • MPC Modifications Driven by Cells--Product Sequencing (p. 352)
  • Choosing an MPC System for a Cellular Work Organization (p. 358)
  • Facilitating Planning and Control by Reducing Complexity (p. 365)
  • Chapter 12 Job Design and Daily Work in Manufacturing Cells (p. 369)
  • What Work Is Like in Cells (p. 369)
  • Do Jobs Change Automatically When You Implement Cells? (p. 373)
  • What Is Job Design? (p. 374)
  • Supervision in Cell Systems (p. 393)
  • Cell Work Characteristics (p. 375)
  • A Decision Framework for Cell Job Design (p. 381)
  • Cells and Teams (p. 389)
  • Chapter 13 Selecting and Training Cell Employees (p. 401)
  • Why Selection and Training Are Different with Cells (p. 401)
  • Selecting Cell Employees (p. 402)
  • Selecting Cell Supervisors and Cell Leaders (p. 419)
  • Training Cell Operators, Leaders, and Supervisors (p. 424)
  • Chapter 14 Compensation Systems for Cell Employees (p. 437)
  • Goals and Characteristics of an Ideal Cell Compensation System (p. 438)
  • Understanding Pay and Pay Systems (p. 442)
  • Compensation Systems Providing Regular Pay (p. 444)
  • Compensation Systems Providing Bonus Pay (p. 453)
  • Cell Compensation in Practice: Combining Pay Systems (p. 460)
  • An Ideal Cell Compensation System (p. 464)
  • Issues in Adopting and Implementing Compensation Systems for Cell Employees (p. 465)
  • Non-Monetary Rewards and Recognition (p. 468)
  • Section 4 Implementing and Improving Cells
  • Chapter 15 Planning for Cell Implementation and Managing the Change (p. 475)
  • Planning for Cells in an Electronics Assembly Plant (p. 475)
  • Managing the Transition to Cells (p. 480)
  • The Role of Project Management in Cell Implementations (p. 491)
  • Chapter 16 Common Problems in the Design, Justification, Implementation, and Operation of Cells (p. 513)
  • Common Cell Design and Justification Problems (p. 514)
  • Common Problems in the Implementation of Cells (p. 523)
  • Common Problems During Cell Operation (p. 529)
  • Chapter 17 Improvement and Evolution of Cells (p. 541)
  • What Is Improvement? (p. 541)
  • Cells: An Ideal Setting for Continuous Process Improvement (p. 548)
  • Some Specific Strategies for Improving Cell Processes (p. 551)
  • Section 5 Extending the Concept--Cells in the Office
  • Building a Culture of Continuous Improvement in Cells (p. 557)
  • Beyond Continuous Improvement--The Forces of Cell Evolution (p. 560)
  • Chapter 18 Reorganizing Office Work Using Cellular Principles (p. 573)
  • Office Operations--The Information Factory (p. 574)
  • What Are Office Cells? (p. 579)
  • Benefits of Office Cells (p. 587)
  • Potential Disadvantages of Office Cells (p. 593)
  • An Eight-Step Process for Designing Office Cells (p. 594)
  • 14 Principles for Designing and Operating Office Cells (p. 604)
  • Making Office Cells Work: Infrastructure Issues and Other Key Challenges (p. 610)
  • Section 6 What's Next?
  • Chapter 19 Future Changes and Challenges (p. 621)
  • A Brief Review (p. 621)
  • Cells in 2020: A Platform for Competitive Manufacturing (p. 622)
  • Gray Areas: Where We Need to Know More (p. 627)
  • Final Words (p. 628)
  • Appendices
  • Appendix A Using Standard Cost per Piece Data to Justify Cells (p. 629)
  • Appendix B How to Make Effective Presentations to Management (p. 633)
  • Appendix C Measurement Checklist (p. 635)
  • Appendix D A Primer on Accounting Systems (p. 637)
  • Appendix E Family Sequencing Procedures (p. 647)
  • Appendix F Job Enlargement and Job Enrichment (p. 655)
  • Appendix G Tips for Effective Cell Employee Selection Interviews (p. 661)
  • Appendix H A Sample of Courses Focused on Basic Cell Concepts, Interpersonal and Problem-Solving Skills, and Coaching and Facilitation (p. 663)
  • Appendix I One Company's Organizational Change Structure (p. 669)
  • Appendix J Process Improvement Opportunity Checklist from a Large Electronics Plant (p. 673)
  • Appendix K Guidelines for Implementing Setup Time Reduction (p. 677)
  • Appendix L A Primer on Functional Flow Charts and Tagging (p. 681)
  • Endnotes (p. 687)
  • References (p. 723)
  • Index (p. 739)

Author notes provided by Syndetics

Nancy Lea Hyer is Associate Professor of Management at Vanderbilt University's Owen Graduate School of Management
Urban Wemmerlov is the Kress Family Wisconsin Distinguished Professor at the School of Business, University of Wisconsin-Madison

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