The 12 Principles of Manufacturing Excellence: A Leader's Guide to Achieving and Sustaining Excellence
Features
- Describes a comprehensive approach to achieving excellence, from board room strategy to shop floor execution
- Facilitates vertical and horizontal organization alignment
- Details a process for tracking progress
- Contains chapters devoted to each manufacturing principle and each leader's role
- Includes a CD with Excel files of a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can be customized to meet readers’ needs
Summary
Explaining how to implement and sustain a top-down strategy for manufacturing excellence, The 12 Principles of Manufacturing Excellence: A Leader’s Guide to Achieving and Sustaining Excellence provides a comprehensive, proven approach for delivering world-class performance while also cultivating the right culture through leadership and mentoring.
Tapping into four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve vertical and horizontal alignment across your organization. He details a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function. Emphasizing the importance of using Lean and Six Sigma tools to improve your business, the book:
- Integrates strategy and leadership development
- Paves a path for culture change–Operator-Led Process Control (OLPC)—that prepares hourly employees to take control of their processes and prepares management to enable them to do it
- Details an audit process for tracking progress and ensuring sustainability
- Includes a CD with color versions of the images in the book as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can all be easily customized for the reader’s use
This resource-rich book will allow you to spell out leadership expectations and provide your employees and associates with a clear understanding of their individual roles. Helping you keep everyone in your organization focused during the quest towards sustainable manufacturing excellence, the accompanying CD supplies the tools you and your team will need to pursue it with passion, confidence, and urgency.
Listen to what Larry Fast has to say about his new book, The 12 Principles of Manufacturing Excellence.
Table of Contents
THE 12 PRINCIPLES OF MANUFACTURING EXCELLENCE
The Manufacturing Excellence Strategy
The Origin of the 12 Manufacturing Principles
The Manufacturing Excellence Strategy
Common Metrics
The Manufacturing Excellence Audit (MEA)
Manufacturing Principle 1: Safety
Stage Summary (Stages 1-4)
Manufacturing Principle 2: Good Housekeeping and Organization
Set in Order
Standardize
Shine
Sustain
Stage Summary (Stages 1-4)
Manufacturing Principle 3: Authorized Formal Systems
Manufacturing Principle 4: Preventive and Predictive Maintenance
Manufacturing Principle 5: Process Capability
Short-Term Actions
Longer-Term Actions
Stage Summary (Stages 1-4)
Manufacturing Principle 6: Product Quality
Standard Work
Stage Summary (Stages 1-4)
Manufacturing Principle 7: Delivery Performance
Manufacturing Principle 8: Visual Management
Manufacturing Principle 9: Continuous Improvement
Manufacturing Principle 10: Communication
Manufacturing Principle 11: Training
Manufacturing Principle 12: Operator-Led Process Control
Principle 2: Housekeeping
Principle 3: Manufacturing Systems
Principle 4: Preventive Maintenance
Principle 5: Process Capability
Principle 6: Product Quality
Principle 7: Delivery Performance
Principle 8: Visual Management
Principle 9: Productivity
Principle 10: Communications
Principle 11: Training
Principle 12: Operator-Led Process Control
Stage Summary (Stages 1 -4)
LEADING MANUFACTURING EXCELLENCE
The Plant Manager’s Role
Anticipation
Initiative
Timely Communications
Feed Your Own Monkeys
Develop Your Own Organization
Properly Administer Company Policies
Make the Numbers
The Manufacturing Manager’s Role
The Materials Manager’s Role
Production Control Office (PCO)
Purchasing or Sourcing
Formal Systems Zealot
Lean Zealot
The Process Engineering Manager’s Role
Capital Appropriations
Systems Infrastructure
Process Engineering—A Key Team Member
The Maintenance Manager’s Role
The Rolling 3-Year Facility Maintenance Plan
Maintenance Staffing
The Quality Manager’s Role
Technical Expert on Quality Improvement Tools
Lead the Change from Firefighting to Fire Prevention
The Customer Advocate on Product Quality
The Human Resource Manager’s Role
Service-Oriented Staff of Experts
Plant Manager’s Confidant
Policy Administration
Environmental Health and Safety
Culture Change Zealot
The Finance Manager’s Role
The Finance Manager’s Role with the Other Plant Staff Managers
Keeper of the Metrics
Capital Investment Watchdog
Systems Integrity Zealot
Shop Floor Visibility
Sustaining Manufacturing Excellence
Appendices:
Appendix A: The 12 Principles of Manufacturing Excellence
Appendix C: Manufacturing Excellence Reading List, 1986–2010
Appendix D: Formulas for Selected Metrics
Index
Appendices on the accompanying CD:
Appendix B: Manufacturing Excellence Audit
Appendix E: Example of a Communications Plan Calendar
Appendix F: Example of a Training Plan
Author Bio(s)
Editorial Reviews
Great template on how to build manufacturing excellence. I can use this with any operation. I already knew most of the tools, but this prescribed approach pulls it all together. … The 12 Principles are very applicable to all functions. … an excellent roadmap for developing and running a world-class operation. It will become my model for continuous improvement. … Larry’s understanding of operations and business management shows well. Clearly he has taken years of valuable experience and pulled it together in a way and format that everyone can use and follow. It’s a great how-to manual.
—Mike Stonecipher, Director of Operational Excellence, Power Partners, Inc.
The Manufacturing Excellence Audit will be a great tool to be used in our organization.
—Jimmy Duncan, Manufacturing Manager, Lincoln Electric
I think I've read at least 100 different books on all the various programs, methods, and techniques that are typically tied to continuous improvement or manufacturing excellence, and yours is the only book that has taken an integrated approach to capture the key principles. I've become a disciple and zealot by reading all those books, attending numerous training seminars and conferences, and being personally involved as a team participant or change agent in many change initiatives. Some very successful, some not so much. Your book has helped validate our own journey within a long standing organization with a history of being very internally focused.
—William (Bill) Fautch, Vice President, Manufacturing, Olin Brass—Mill Products, a Division of Global Brass & Copper, LLC
I just received your book and I am almost through reading it already. Fantastic! It's a must read for anyone in manufacturing.
Peter Olmsted, Chief Talent Officer, Definity Partners; Former SVP Human Resources, General Cable Corporation
