World Class Manufacturing

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9781416592549: World Class Manufacturing
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In his best-selling book Japanese Manufacturing Techniques, Richard J. Schonberger revolutionized American manufacturing theory and, more important, practice. In that breakthrough book, he revealed that Japanese manufacturing excellence was not culturally bound. Offering the first demystified explanation of the simple techniques that fueled Japan's industrial success, he demonstrated how the same methods could be put to work as effectively in U.S. plants. Now, in World Class Manufacturing, Schonberger returns to tell the success stories of nearly 100 American corporations -- including Hewlett-Packard, Harley-Davidson, General Motors, Honeywell, and Uniroyal -- that have adopted the famed just-in-time production and "total quality control" strategies. Based on his firsthand experience as a major consultant to American industry, he examines how they did it -- and illustrates how the same concrete, specific steps used by these top companies can be implemented in any factory today. What's more, Schonberger shows that his bold concepts and reforms apply equally to all industries, whether the product is computers, pasta, or trucks, and to all divisions -- from manufacturing and engineering to accounting and marketing. According to Schonberger, world-class manufacturing depends on blended management -- rather than domination by a separate group of managers -- which marshalls resources for continual rapid improvement. To achieve world-class status, companies must change procedures and concepts, which in turn leads to recasting relations among suppliers, purchasers, producers, and customers. Acknowledging the difficulty inherent in such changes, Schonberger stresses that employee involvement and interaction, both on the shop floor and in the decision-making/problem-solving process, is key. Wary of those who view improvement in terms of modernizing equipment, he points out that making maximum use of people and current machinery is a company's first priority; automation, if necessary, should come much later. World Class Manufacturing also includes Schonberger's 17-point action agenda to guide innovators toward manufacturing excellence, from getting to know the customer to cutting the number of suppliers, reducing error in production, and deciding when and how to automate. Indispensable for all manufacturing innovators who aim to keep ahead of the competition, this inspiring, groundbreaking volume does much more than just recommend or theorize about the new manufacturing approach. Plainly, realistically, and logically, it explains how it's done.

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Product Description:

Since the invention of double-entry bookkeeping, managers have judged a company's worth by sales and profits. Now Richard Schonberger exposes the fallacies of this timeless practice. Schonberger's pathbreaking new research reveals that, from 1950 to 1995, while "financials" dipped and soared repeatedly, industrial decline and ascendancy correlated perfectly with inventory turnover -- one of two key nonfinancial indicators and a bedrock measure, along with customer satisfaction, of a company's power, strength, and value. In this immensely readable book, he captures these new metrics -- the true predictions of future success -- in 16 customer-focused principles created from self-scored reports supplied by over 100 pioneering manufacturers in nine countries. Armed with new world-class benchmark data, Schonberger redefines excellence in terms of competence, capability, and customer-focused, employee-driven, data-based performance.

Review:

Eric Olsen Worldwide Manufacturing Education Manager, Hewlett Packard Components Group Dick Schonberger's call to "manage the basics, watch the results," plays well in Hewlett Packard's environment where we believe people want to do a good job. Focusing on the right metrics at each level tells them what a good job is.

John M. Burnham

CFPIM Regional Vice President, American Production and Inventory Control Society

Richard Schonberger has successfully addressed the next steps in the journey toward becoming world-class manufacturers -- issues of holistic view and perspective, effective interfacing among functional areas, and demonstrated results that demolish the arguments that "we're different" and "it can't be done." Each of his chapter topics is logically and persuasively developed. In a word, I wish I had written this book.

Philip Gray

Vice President, Defense Systems & Electronics Group, Texas Instruments

"World Class Manufacturing" brings together for the first time all the programs and approaches we at Texas Instruments and other companies have been working toward for the past six years -- total quality control, just-in-time manufacturing, statistical process control, manufacturing cells, and, most important, employee involvement. It will be required reading for managers who have marketing, product design, and manufacturing responsibilities.

John P. Robb

Vice President, Manufacturing Monsanto Electronic Materials Company

The commonsense examples and guidelines on the "how to" of total quality control Richard Schonberger provides in "World Class Manufacturing" will enable us to move beyond manufacturing excellence to business excellence. Schonberger's first book, "Japanese Manufacturing Techniques," provided the missing link in our overall quality program and is on the "must read" list for all our manufacturing line personnel. "World Class Manufacturing" will be required reading for "all" functions within our company.

Philip Gray Vice President, Defense Systems & Electronics Group, Texas Instruments "World Class Manufacturing" brings together for the first time all the programs and approaches we at Texas Instruments and other companies have been working toward for the past six years -- total quality control, just-in-time manufacturing, statistical process control, manufacturing cells, and, most important, employee involvement. It will be required reading for managers who have marketing, product design, and manufacturing responsibilities.

John M. Burnham CFPIM Regional Vice President, American Production and Inventory Control Society Richard Schonberger has successfully addressed the next steps in the journey toward becoming world-class manufacturers -- issues of holistic view and perspective, effective interfacing among functional areas, and demonstrated results that demolish the arguments that "we're different" and "it can't be done." Each of his chapter topics is logically and persuasively developed. In a word, I wish I had written this book.

John P. Robb Vice President, Manufacturing Monsanto Electronic Materials Company The commonsense examples and guidelines on the "how to" of total quality control Richard Schonberger provides in "World Class Manufacturing" will enable us to move beyond manufacturing excellence to business excellence. Schonberger's first book, "Japanese Manufacturing Techniques, " provided the missing link in our overall quality program and is on the "must read" list for all our manufacturing line personnel. "World Class Manufacturing" will be required reading for "all" functions within our company.

Robert J. Saldich President and CEO (Retired), Raychem Corporation Richard Schonberger taught us in 1984 about Japanese manufacturing and launched Raychem on its continuing quality journey. Now he takes us into a whole new dimension. The book is stuffed with wonderful insights, ideas and approaches. It is a rare original contribution to the literature.

Kelly Hoffmann Vice-President Pressure Operations, Measurement Division, Rosemount Inc. Dr. Schonberger created a new paradigm for how a factory should operate in "World Class Manufacturing." Now he helps us see the world of manufacturing differently once again, using inventory turnover as the lens.

Arthur D. Wainwright Chairman and CEO, Wainwright Industries, Inc. A powerful book of trenchant and perceptive observation needed to prosper in the fast-approaching 21st century.

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