The manufacturing and service sector needs to resolve a lot of issues relating to products, process and service in everyday operation. Successful resolution depends on the methodology, rigor and systematic implementation techniques. The essential purpose of this book is to impart the necessary knowledge to the reader about concepts in six sigma problem-solving providing sufficient knowledge of problem lifecycle and ways to address the various issues arising therein. The 7 QC tools and A3 strategy are described and analyzed in detail with various examples encompassing a step by step approach a professional must know to address a problem in an industrial engineering set up. Key Features Conceptualizes six sigmas problem-solving providing sufficient knowledge of problem lifecycle and ways to address the various issues for manufacturing industry professionals Enables effective use of 7 QC tools for solving problems Addresses the problem- solving part very specifically in all the contexts of PDCA cycle of improvement, DMAIC methodology of organizational transformation, and TPM & TQM culture of productivity and quality improvement Written with A3 theme throughout enabling each problem-solving tool to follow a structured approach Includes relevant and practical examples and applications

The never-ending global search for a country with a low labour wage is almost bottoming out. The so-called labor-oriented apparel manufacturing industry is poised to change. Due to fierce global pressure on reducing price and lead time, the textiles and apparel producers will have to banish all waste from their supply chain. Lean manufacturing which removes waste and smoothens the process flow is gaining popularity among textiles and apparel producers and will be a key element for the survival of the industry in the years ahead. An overview of various lean tools with a balanced mix of conceptual knowledge and practical applications in the context of apparel manufacturing Valuable industry information which managers and engineers can follow themselves without the need to hire outside consultants Case studies and examples from apparel manufacturing demonstrating how lean tools are being used successfully by leading organizations; an academician’s delight Possible use cases of several lean tools having potential use in the apparel manufacturing scenario

This book introduces fundamental, advanced, and future-oriented scientific quality management methods for the engineering and manufacturing industries. It presents new knowledge and experiences in the manufacturing industry with real world case studies. It introduces Quality 4.0 with Industry 4.0, including quality engineering tools for software quality and offers lean quality management methods for lean manufacturing. It also bridges the gap between quality management and quality engineering, and offers a scientific methodology for problem solving and prevention. The methods, techniques, templates, and processes introduced in this book can be utilized in various areas in industry, from product engineering to manufacturing and shop floor management. This book will be of interest to manufacturing industry leaders and managers, who do not require in-depth engineering knowledge. It will also be helpful to engineers in design and suppliers in management and manufacturing, all who have daily concerns with project and quality management. Students in business and engineering programs may also find this book useful as they prepare for careers in the engineering and manufacturing industries. Presents new knowledge and experiences in the manufacturing industry with real world case studies Introduces quality engineering methods for software development Introduces Quality 4.0 with Industry 4.0 Offers lean quality management methods for lean manufacturing Bridges the gap between quality management methods and quality engineering Provides scientific methodology for product planning, problem solving and prevention management Includes forms, templates, and tools that can be used conveniently in the field

This book is designed to assist industrial engineers and production managers in developing procedural and methodological engineering tools to meet industrial standards and mitigate engineering and production challenges. It offers practitioners expert guidance on how to implement adequate statistical process control (SPC), which takes account of the capability to ensure a stable process and then regulate if variations take place due to variables other than a random variation. Powerful engineering models of new product introduction (NPI), continuous improvement (CI), and the eight disciplines (8D) model of problem solving techniques are explained. The final three chapters introduce new methodological models in operations research (OR) and their applications in engineering, including the hyper-hybrid coordination for process effectiveness and production efficiency, and the Kraljic-Tesfay portfolio matrix of industrial buying.

This book provides a short and concise introduction to lean principles and key concepts. It is written in simple engineering language with the novice in mind. Where possible, the themes and principles are supported concerning examples across engineering and diagrams and drawings to highlight the core teachings. It is an ideal introduction or refresher for engineers of any person working in the manufacturing or pharmaceutical industries. This book may give you: Lean Tools For Engineers: Lean Principles Every Engineer Should Know Lean Methodology Engineers: The Principles Of Lean Manufacturing Lean Principles For Engineers: Key Lean Manufacturing Principles

This book brings a fresh new approach to practical problem solving in engineering, covering the critical concepts and ideas that engineers must understand to solve engineering problems. Problem Solving for New Engineers: What Every Engineering Manager Wants You to Know provides strategy and tools needed for new engineers and scientists to become apprentice experimenters armed only with a problem to solve and knowledge of their subject matter. When engineers graduate, they enter the work force with only one part of what’s needed to effectively solve problems -- Problem solving requires not just subject matter expertise but an additional knowledge of strategy. With the combination of both knowledge of subject matter and knowledge of strategy, engineering problems can be attacked efficiently. This book develops strategy for minimizing, eliminating, and finally controlling unwanted variation such that all intentional variation is truly representative of the variables of interest.

Modern Manufacturing Methodologies have undergone three different evolutionary stages over the past 200 years. Before there were modern manufacturing plants, the world only knew skilled craftsmen who labored as individuals in very small groups to produce goods and services. The first factory evolution came about when James Watt invented the steam engine. Metal cutting, forming and assembly machines were co-located near streams or rivers forming what we now call the Job Shop or the American Armory System. The second factory evolution began when Henry Ford introduced the first modern assembly line using interchangeable parts and standardized manufacturing procedures. This gave rise to the modern flow shop, which reached its zenith during WWII. In the late 1970s, the third industrial evolution began when Taiichi Ohno and the Toyota Motor Company introduced what we now call Lean Manufacturing...and the world came. Over the last 40 years, all forms of manufacturing and service systems have embraced the concepts of Lean Thinking and proved its superiority to traditional manufacturing and service systems design. This book defines and characterizes a new breed of Manufacturing Engineer which we call the Lean Engineer. The Lean Engineer has roots in traditional Industrial engineering, but is also well trained in six-sigma methodologies and understands lean to green factory design principles. However, Lean Engineering transcends and redefines the classic Industrial engineer. Principles of Lean systems design, U-shaped Lean manufacturing cells, Linked Cell Manufacturing System design and Mixed Model final assembly lines are unique Lean Engineering strategies. This book attempts to define for the first time a new manufacturing engineering discipline called the Lean Engineer. This book: Introduces Lean System Design principles Demonstrates the conversion of traditional manufacturing lines into U-shaped Lean Cells Contrasts push versus pull manufacturing strategies Covers Balancing, Leveling and System synchronization Demonstrates Value Stream Mapping and the 7-Lean analysis tools Provides an introduction to Queuing Network Analysis for single and multiple product flows ....and many more Principles which define the Lean Engineer