Pries / Quigley Reducing Process Costs with Lean, Six Sigma, and Value Engineering Techniques

1. Auflage 2013
ISBN: 978-1-4665-9763-1
Verlag: Taylor & Francis
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 365 Seiten

A company with effective cost reduction activities in place will be better positioned to adapt to shifting economic conditions. In fact, it can make the difference between organizations that thrive and those that simply survive during times of economic uncertainty. Reducing Process Costs with Lean, Six Sigma, and Value Engineering Techniques covers the methods and techniques currently available for lowering the costs of products, processes, and services.

Describing why cost reductions can be just as powerful as revenue increases, the book arms readers with the understanding required to select the best solution for their company’s culture and capabilities. It emphasizes home-grown techniques that do not require the implementation of any new methodologies—making it easy to apply them in any organization.

The authors explain how to reduce costs through traditional Lean methods and Lean Six Sigma. They also present Six Sigma cost savings techniques from Manufacturing Six Sigma, Services Six Sigma, and Design for Six Sigma. The book also presents optimization techniques from operations research methods, design experiment, and engineering process control.

Helping you determine what your organization’s value proposition is, the text explains how to improve on the existing proposition and suggests a range of tools to help you achieve this goal. The tools and techniques presented vary in complexity and capability and most chapters include a rubric at the start to help readers determine the levels of competence required to perform the tasks outlined in that chapter.

Zielgruppe

Line manager, product developers, and project managers.

Autoren/Hrsg.

Pries, Kim H.

Quigley, Jon M.

Fachgebiete

• Wirtschaftswissenschaften Betriebswirtschaft Bereichsspezifisches Management Produktionsmanagement, Qualitätskontrolle
• Wirtschaftswissenschaften Betriebswirtschaft Management Prozessmanagement
• Wirtschaftswissenschaften Betriebswirtschaft Management Qualitätsmanagement, Qualitätssicherung (QS), Total Quality Management (TQM)

Inhaltsverzeichnis

Introduction
The Use of Rubrics

Questions to Ponder

Cost Improvement Scenario Situation Objective Action Results Aftermath

A Brief Overview of Value Engineering

Product Life Cycle

What Is Value?

Cost Improvement Challenge
Cost Avoidance

Cost Reduction
Profit Improvement

Green and Corporate Stewardship Are the Same

The Case for Cost Reductions
Planning for and Managing a Value Improvement Project Project Concept Project Information Project Business case
Conclusion

Saving Money with Homegrown Ideas
Rubric for Homegrown Ideas

Questions to ponder

Cost Improvement Scenario Situation Objective Action Results Aftermath

Your People Matter

Laboratory Equipment

Production Equipment

Production Test Equipment

Logistics Material

Engineering

Marketing

Accounting/Finance
Procurement

A. Financial Determination

Brainstorming Product, Process or Service Preparation for Critique Numbers Count Suspend Judgment Build on Ideas

Mind Mapping

Selection Method Weighted Matrix such a Pugh Matrix Majority Decision Voting Decision Consensus Rating Delphi Method Nominal Group Technique Group Passing Technique De Bono and his Thinking Hats Advocacy and inquiry Strategic Assumption Surfacing And Testing (SAST) Team Syntegrity Facilitation

ARBITRARY COST DOWN APPROACH

Rubric for Costing Down

Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath

Why the Arbitrary Cost Down Approach

Cost Down Process

Cost Management Cycle

When to Use
The Greedy Approach
Cost Generators
Generators and Cost Cutting

The Isuzu Approach to Tear Downs
Rubric for Tear Downs
Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath

What is the Isuzu approach Dynamic Tear Down Cost Tear Down Material Tear Down Matrix Tear Down Process Tear Down Static Tear Down

Why use this technique

Tear Down Example Design for Assembly Value Analysis Contribution to the Tear down Process Value analysis Tear down and Improvement/Innovation Value analysis Tear down Method and its Components Recognizing Parts Suppliers Competitive Capability Collecting New Suggestions for Improvement Case Study

The DOD Approach

Rubric for DoD Approach

Questions to Ponder

Cost Improvement Scenario Situation Objective Action Results Aftermath

Benefits

Function

Worth

Cost

Value

Effective Value Engineering Programs

Cost Analysis Variance Analysis Ratio Analysis Trend analysis Management analysis

Classical Value Analysis / Value Engineering Techniques

Rubric for Classical Techniques
Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath

Benchmarking Is Benchmarking Valuable? Performance Benchmarking Benchmarking Process

Classical Techniques
Rubric for FAST Approach

Questions to Ponder

Cost Improvement Scenario Situation Objective Action
Results Aftermath
FAST introduction
Creating a FAST model

Saving Money with Six Sigma Projects

Rubric for Six Sigma Projects

Questions to Ponder

Cost Improvement Scenario Situation Objective Action Results Aftermath

What is Six Sigma?
How Does Six Sigma Relate to Value Engineering?
The Phases of Six Sigma

Choosing Six Sigma Projects

Costing Six Sigma Projects

Using Design for Six Sigma

Rational Expectations From Six Sigma Enterprise Process Management and Metrics Define Measure Analyze Improve Control Design for Six Sigma (DFSS) Frameworks and Methodologies

Saving Money with Lean Manufacturing

Rubric for Lean Manufacturing
Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath

What Is Lean?
Production Organization or 5S

Lead Time Reduction

Kanban

Demand Segmentation

Production Scheduling
Inventory Reduction
Lean Six Sigma Lean Six Sigma Overview Lean Six Sigma Goals LSS Project Management Team Organization & Dynamics Defining Opportunities Measurement Techniques Analysis Techniques Improvement Techniques Control Concepts Design Improvement

Saving Money with Optimization
Rubric for Optimization

Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath
Operations Research Approaches Evolution of Operations Research in Academics Origin, History, and Developments Operational Research Activities The Operations Research Approach Significance of Operations Research Operations Research in Manufacturing The Operations Research Experience in the US Growth of Operation Research in Different Sectors Challenges in Operations Research Future Trends Conclusion

Genetic Algorithms

Particle Swarm Optimization (PSO)

Ant Path Optimization
Simulations

Regaining Money with Cost Recovery

Rubric

Questions to Ponder

Cost Improvement Scenario Situation
Objective Action Results Aftermath
What is Cost Recovery?
When to Use Cost Recovery

Benefits of Cost Recovery
Steps to Cost Recovery
Two-way Cost Recovery

Other Methods
Rubric for Other Methods

Questions to Ponder
Cost Improvement Scenario Situation Objective Action Results Aftermath
Other Tools Project Management What is DFA? Design for Manufacturing Rapid Prototyping

Finding Cost Reductions

Rubric for Finding Cost Reductions

Questions to Ponder

Cost Improvement Scenario Situation Objectives Actions Results Aftermath

Finding Cost Reductions in the Plant Operations Engineering Accounting/Finance Purchasing Marketing Project Management Human resources

Finding cost reductions in the office Office supplies Equipment Copies/printing Paper/paperless

Finding cost reductions in education Operations Accounting/Finance Purchasing Project management Human resources Sports and Extra-curricular activities
Finding cost reductions on the personal side Used versus new material Quantity versus quality Food Clothing Furniture Housing Vehicles

When Cost Improvement Goes Wrong
Rubric

Questions to Ponder

Cost Improvement Scenario 1 Situation Objective Action Results Aftermath

Cost Improvement Scenario 2 Situation Objective Action Results Aftermath
Cost Improvement Scenario 3 Situation Objective Action Results
Aftermath
Material Substitution is a poor fit Bulb removal tool Vehicle Diagnostics Connector Supplier selection Scope or Design Review Drop in replacement Reuse of material

Über Autor(innen)

Kim H. Pries & Jon M. Quigley
Co-Founders, Value Transformation, LLC