Focus on Waste Reduction
           • Process and methods
           • Movement and storage of materials
           • Defects
           • Waiting time
           • Overproduction
           • Inventory
  Arnold, Chapman, & Clive: Intro Materials                    © 2008 Pearson Education, Upper Saddle River, NJ 07458. 
  Management, 6th ed.                                          All Rights Reserved.
                 Poke-Yoke (Fail Safe) Design
           • Change the process or resources
           • Try to eliminate reliance on human 
                experience and knowledge
           • Examples:
                 – Color-coded parts
                 – Templates
                 – Use of counters on operations
                 – Design plugs to only be inserted one way
  Arnold, Chapman, & Clive: Intro Materials                    © 2008 Pearson Education, Upper Saddle River, NJ 07458. 
  Management, 6th ed.                                          All Rights Reserved.
                              Focus on Work Flow
           • Flow manufacturing or work cells
           • Work toward flexibility
                 – Process flexibility
                 – Machine flexibility
                 – Operator flexibility
                 – Quick changeover with short setup times
  Arnold, Chapman, & Clive: Intro Materials                    © 2008 Pearson Education, Upper Saddle River, NJ 07458. 
  Management, 6th ed.                                          All Rights Reserved.
                Other Important Waste Reduction 
                                                   Actions
           • High product and process quality
                 – Six Sigma quality approach
           • Total productive maintenance
           • Uninterrupted flow of material with 
                uniform plant loading
           • Continuous process improvement
  Arnold, Chapman, & Clive: Intro Materials                    © 2008 Pearson Education, Upper Saddle River, NJ 07458. 
  Management, 6th ed.                                          All Rights Reserved.
                                 Focus on Suppliers
           • Work toward supplier partnering
                 – Supplier selection
                 – Supplier certification
           • Three key factors
                 – Long-term commitment
                 – Trust
                 – Shared vision
  Arnold, Chapman, & Clive: Intro Materials                    © 2008 Pearson Education, Upper Saddle River, NJ 07458. 
  Management, 6th ed.                                          All Rights Reserved.