Drawing on 40 years of application experience at one of the world's largest chemical and materials manufacturers, King provides the first comprehensive resource written explicitly for change agents within the process industries.

While Lean practices have been successfully implemented into the process industry with excellent results for over 20 years (including the author‘s own award winning example at Exxon Chemical), that industry has been especially slow in adopting Lean. Part of the problem is that the process industry needs its own version of Lean. The larger part of t

Providing a framework that highlights waste and its negative effects on process performance, value stream maps (VSMs) are essential components for successful Lean initiatives. While the conventional VSM format has the basic structure to effectively describe process operations, it must be adapted and expanded to serve its purpose in the process indu

Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

Lean manufacturing is the single most effective way to increase sales, cut costs, improve margins, and secure the future of a business. The problem is that the principles and philosophies of lean manufacturing are geared strictly to mass production operations and can be ineffective, even detrimental, for smaller job shops and make-to-order businesses. Now, Speed to Market delivers a proven approach for smaller suppliers who want to successfully cut their lead time and trigger profitable growth. Completely updated and expanded, the book explains how to: * Apply the principles of pull, flow, and the elimination of waste to every area of the company, at every stage from quotes to cash* Implement a continuous improvement process while sidestepping the typical implementation pitfalls* Ease scheduling problems* Improve performance and profitability using the book's practical concepts, process analysis tools, and perspective-enhancing techniques and much more

Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While, a number of innovators have successfully applied Lean principles to these industries over the last two decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on 40 years of application experience at one of the world's largest chemical and materials manufacturers, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity -Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operationsExplains how to adapt value stream mapping for process operationsShows how to identify the root causes of bottlenecks, and systemically eliminate themProvides process-oriented modifications that will enhance the usefulness of Cellular Manufacturing, Heijunka Production Leveling, and Pull Replenishment Systems Discusses the role of process operations management in a Lean strategy Whether you are manufacturing consumer products such as foods, paints, and pharmaceuticals, or materials such as bulk chemicals, sheet goods, and synthetic fibers, this book shows you how to achieve that enviable level of performance where continual improvement becomes inherent to your processes.

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