Title Systems for Manufacturing Excellence
Subtitle Generating efficient and reliable manufacturing operations
Author Nick Rich, Mohamed Afy Shararah
ISBN 9780749496999
List price GBP 39.99
Price outside India Available on Request
Original price
Binding Paperback
No of pages 344
Book size 152 X 235 mm
Publishing year 2020
Original publisher Kogan Page Limited
Published in India by .
Exclusive distributors Viva Books Private Limited
Sales territory India, Sri Lanka, Bangladesh, Pakistan, Nepal, .
Status New Arrival
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Many production managers have de-stocked excessively large inventories, gone lean, experimented with continuous improvement processes and introduced new working practices. These interventions have largely failed. Businesses have also failed to invest in the workforce that undertakes improvements. This means that cash flow stops quickly, stocks are depleted to zero and customers lose confidence.

Systems for Manufacturing Excellence looks at how people and technology work effectively together to generate high performance manufacturing and service operations. Not everyone is a Toyota but that does not mean we cannot learn from such businesses. The book will present a logic, variety of approaches and methods that underpin the different models of high performance used by ‘world class’ businesses. The authors use examples from their training with Toyota, work with Tesco, and many world class manufacturing businesses that form their research agenda. The book will help teams run each part of their production process for effectiveness and efficiency, with a high level of discipline that supports excellence in performance.

Key features at a glance:

  • Examines the real secrets of highly effective production processes in winning organizations, such as Rolls Royce, Toyota and Land Rover, as well as Tesco and Unilever
  • Explains socio-technical systems and their design through in-depth case studies of best practice
  • Investigates high performing organisations and their use of six sigma and lean manufacturing
  • Presents tools to help managers improve processes and the sustainability of improvement such as sand cone models and the supportive model of manufacturing


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Chapter 1: The modern competitive landscape: The pursuit of higher value added through excellence in manufacturing • IntroductionThe money-making ecosystem • Cash flow is fundamental to manufacturing excellence • Concepts of manufacturing excellence • The management of quality as a competitive priority • Value-adding and the cash flow cycle • Key lessons of manufacturing excellence • In summary • Further reading • Notes

Chapter 2: A history of manufacturing systems excellence • Introduction Modes of manufacturing • The history of manufacturing • Craft production and individual expertise • Mass production and the management prerogative • The process-based approaches to manufacturing • A question of fit • In summary • Further reading • Notes

Chapter 3: Understanding the context for manufacturing excellence • Introduction • The four basic Vs • Variety and mix of products that the technology can output • Adding two more Vs to the feasible manufacturing solution • Adding more Vs • A systems approach to manufacturing and protective buffers • Not low, not high — just medium really! • In summary • Further reading • Notes

Chapter 4: Measures of flow for operational excellence • IntroductionThe fragile manufacturer and supply chain • Strategies for gaining flow • Gaining flow through effective industrial engineering • Problems and inhibitors to flow after initial product designs and industrial engineering • Typical measures of flow • Operations flow effectiveness • In summary • Notes

Chapter 5: Mapping processes for manufacturing excellence • Introduction • The benefits of mapping • Types of map • Levels of mapping • Mapping within the factory • The value of combining maps • In summary • Notes

Chapter 6: High-performance and high-reliability manufacturing • IntroductionSystems theory • Operations and manufacturing strategy • Communications system • Strategy, planning, and short-term information sharing • The technical system • The social system • Learning and improvement system • The supply chain relationships • Systems of manufacturing excellence • In summary • Notes

Chapter 7: Operations strategy, policy deployment and the learning organization • Introduction • The old approach to manufacturing strategy and deployment of policies • Hoshin Kanri/policy deployment • Step-by-step policy deployment • The X chart matrix • The A3 project chart • In summary • Further reading • Notes

Chapter 8: Social systems and continuous improvement • Introduction • The human side of the manufacturing excellence company • The value of roles • The new HR approach • Teams and improvement • The impact of human error • In summary • Notes

Chapter 9: The technical delivery and material flow subsystem • Introduction • The first set of decisions: From product to process routing • The key decisions of the onion • Designing the actual operations and daily flow of product • Workplace discipline and control • Visual management • In summary • Notes

Chapter 10: System reliability and protecting flow • Introduction • Maintenance management: A neglected capability • Maintenance strategies • The consequence of catastrophe • Value and role • TPM: Goals and improvement approaches • Industry 4.0 and maintenance • The ‘lights out’ factory • In summary • Further reading • Notes

Chapter 11: Supply chain coupling • Introduction • Suppliers: From hated adversary to trusted partner • What is the supply chain? • Relationships with suppliers • The cost of developing suppliers • Measuring supplier performance • Keeping materials moving • The smart factory • Single supplier integration and learning • In summary • Notes

Chapter 12: Conclusions and final thoughts • Reinventing the organization • Economic viability and environmental sustainability • The modern socio-technical system • Closing comment


About the Authors:

Nick Rich is Professor of Socio-Technical Systems Design at Swansea School of Management. He is an academic with a specialist interest in high performance and highly reliable businesses. He has gained international acclaim and has received a significant number of awards for his research work.

Mohamed Afy Shararah is an industrial engineer. He led projects with InnovateUK to deliver a step-change in productivity through embedding new capabilities in innovative manufacturing techniques and cutting-edge engineering product design. He also collaborated with African, Asian, European, and North American businesses on improvement projects in the areas of Lean Manufacturing and Circular Economy.

Target Audience:

The book will help teams and production managers run each part of their production process for effectiveness and efficiency, with a high level of discipline that supports excellence in performance.

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