The Manufacturing Manager
A Comprehensive Guide for Professionals in Industry
Published on 10. May 2001
Book
Hardback
952 pages
978-1-86076-202-4 (ISBN)
Description
This volume offers a complete guide aiming to give managers immediate access to all aspects of the manufacturing process. It should appeal to all managers of all disciplines throughout the manufacturing industry (i.e. quality, production, purchasing, accounting etc). It should also be of interest to management consultants and business schools amongst others.
Reviews / Votes
"This book contains the most all-encompassing coverage of the theories and practice I have encountered." -Sir John Harvey-Jones MBEMore details
Language
English
Place of publication
Cork
Ireland
Target group
Professional and scholarly
Illustrations
Illustrations
Dimensions
Height: 234 mm
Width: 156 mm
Thickness: 46 mm
ISBN-13
978-1-86076-202-4 (9781860762024)
Copyright in bibliographic data is held by Nielsen Book Services Limited or its licensors: all rights reserved.
Schweitzer Classification
Person
David Crabtree is the principal instructor of GMCS Ltd. IIe previously worked in production control and production management roles within a number of companies, including Henderson Engineering, Texaco and ICI (Zeneca). He is a Chartered Engineer, a Fellow of the British Computer Society and a Fellow of the Institute of Operations Management.
Content
Contents Acknowledgements ix Preface xi Chapter 1: The Manufacturing Company 1 1.1 The Legal Framework of the Company 1 1.2 The Directors and Managers of the Company 6 1.3 Methods of Trading 9 1.4 Company Tasks - An Overview in Relation to this Book 14 Chapter 2: Sales and Marketing 21 2.1 Marketing 21 2.2 Innovation 30 2.3 Selling and Sales Management 35 2.4 Sales Order Processing 40 2.5 Sales Forecasting 44 Chapter 3: Product Innovation 51 3.1 The Product Brief 51 3.2 Product Design - The Principal Stages 53 3.3 "Design for" Manufacture 62 3.4 Failure and Reliability 74 3.5 Bills of Materials Management 81 Chapter 4: Sales Forecasting 87 4.1 Introduction to Short-term Forecasting 87 4.2 Patterns of Data 89 4.3 Sales Demand Data 101 4.4 The Naive Forecasting Family 108 4.5 The Causal Forecasting Family 120 4.6 Forecasting Management 130 4.7 Dealing with Sporadic (Intermittent) Demand 133 Chapter 5: Safety Stock 139 5.1 Justification for Safety Stock 139 5.2 Factors Involved in Safety Stocks 141 5.3 Customer Service Targets 156 5.4 Defining Customer Service in Theoretical Terms 157 5.5 The Safety Stock System 174 Chapter 6: Master Plan Formulation 179 6.1 Definitions 179 6.2 Overview of the MPS Process 184 6.3 S&OP I: Business Review 189 6.4 S&OP II: Resource Requirements Planning 193 6.5 Detailed Master Scheduling I 199 6.6 Detailed Master Scheduling II (Rough Cut) 208 6.7 Commitment, Release, Commitment 213 Chapter 7: Master Plan Management 215 7.1 Consuming the Forecast 216 7.2 Available-to-Promise 228 7.3 Master Scheduling New Products 243 Chapter 8: Assemble-to-Order ("Quick Response") 247 8.1 Introduction 247 8.2 Redesign for Assemble-to-Order 249 8.3 The Modular Bill and Option Choice 261 8.4 The Super Bill 265 8.5 The FAS and Master Scheduling 267 8.6 Forecasts and Option Overplan Amounts 274 8.7 Quick Response 278 Chapter 9: Materials Planning 287 9.1 Order Point 288 9.2 Planning and Manufacturing 290 9.3 Levels in the Bill of Materials 293 9.4 The Calculation of Material Requirements 298 9.5 Gross Requirements to Plans 311 9.6 Planning Rules 314 Chapter 10: Closed-Loop MRP 331 10.1 Defining Closed-Loop MRP 331 10.2 Plan Types in MRP 333 10.3 The MRP Rescheduling Logic 340 10.4 Total Regeneration and Net Change 349 Chapter 11: Shop Floor Control 353 11.1 Work Scheduling 353 11.2 The Release of Orders to the Shop 356 11.3 Job Despatching Rules (Job Prioritising) 369 11.4 Lead Time Management 378 11.5 The Shop Floor Information System 383 Chapter 12: Advanced Planning Systems 401 12.1 Introduction 401 12.2 Discrete Job Systems 409 12.3 Continuous Flow Systems 430 12.4 Bottleneck APS Systems 447 Chapter 13: Total Quality Control 471 13.1 The Imperative of Total Quality 471 13.2 Total Quality in the Manufacturing Company 486 13.3 ISO 9000:2000 503 Chapter 14: Statistical Quality Control (SQC) 513 14.1 SPC - The Statistical Basis 514 14.2 Using the Variable Control Chart 532 14.3 The Attribute Control Charts 545 14.4 Raw Material and Product Control 555 Chapter 15: Just-in-Time 581 15.1 Two Definitions 581 15.2 Establishing Production Rates 584 15.3 SMED and Fast Changeovers 589 15.4 Plant Organisation 598 15.5 Kanban 608 15.6 Equipment Maintenance 621 15.7 Workplace Management 632 Chapter 16: Purchasing 635 16.1 Suppliers 635 16.2 Order Placement 646 16.3 The Carriage and Receipt of Goods 660 16.4 Price and the Marketplace 670 16.5 Foreign Purchases 679 Chapter 17: Finance and Costing 693 17.1 Financial Accounts 693 17.2 Assets 707 17.3 The Evaluation and Acquisition of Assets 714 17.4 Cost Accounting 722 Chapter 18: The Stores and Stock Records 757 18.1 Stores Organisation 758 18.2 Stores Operations 770 18.3 Stock Records Accuracy 775 18.4 Cycle Counting 784 Chapter 19: Human Resources 803 19.1 The Organisation 804 19.2 Reward Management 817 19.3 Working Relationships 840 19.4 Health and Safety 847 Chapter 20: Distribution 857 20.1 The Distribution Network 858 20.2 The Replenishment of the Network 876 20.3 Network Transshipments 890 20.4 Transport of the Goods 900 Selected Bibliography 905 Index 909