World Class Manufacturing Casebook [Paperback]

This casebook, designed as a companion volume to Richard J. Schonberger'sWorld Class Manufacturing: The Lessons of Simplicity Applied,contains 26 cases that let students of WCM concepts solve actual JIT and TQC implementation problems in a wide variety of manufacturing and corporate settings. For readers with specific concerns, each case lists the topics covered (i.e., kanban, total preventive maintenance, partnership with customer) and each case includes questions on issues that companies commonly face in implementing WCM concepts. Dr. Schonberger also explains two JIT and TQC concepts not previously published -- micro-JIT analysis of shop-floor conditions by ratios and the naturalistic approach to quality improvement.Chapter 1

HyGain-Telex: Analysis for JIT Production

Case topics:

Lead-time-to-work-content ratio

Pieces-to-work-stations ratio

Distinction between preventive maintenance and setup

Frequency of delivery

Kanban

Statistical process control

Total preventive maintenance

Simplifying the schedule

Partnership with customer

Cellular manufacturing

The HyGain-Telex plant in Lincoln, Nebraska, manufactures antennas. It currently has a U.S. Army contract for Model X32 antennas. The contract requires a production rate of two hundred Model X32s per day. The contract quantity may be changed quarterly.

Chris Piper, the foreman, is collecting data for a JIT project. Piper has selected the X32 antenna base (not the whip part of the antenna, which is fairly simple) for the JIT project. Exhibit 1-1 is a photograph of the base.

Manufacture of the X32

There are several stages of manufacture for the X32 base, which is a cylinder 6 inches in diameter and 10 inches high. These are the basic production processes, and their standard times, with which Piper was concerned:

* Mold the Lexan plastic base. Some holes are molded into the base by use of core plugs. 2.50 minutes.

* Drill and lC4