Ortiz - The cell manufacturing playbook: a step-by-step guideline for the lean practitioner
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The Cell Manufacturing Playbook: A Step-by-Step Guideline for the Lean Practitioner
Chris A. Ortiz
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
2015 by Taylor & Francis Group
CRC Press is an imprint of Taylor & Francis Group, an Informa business
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Version Date: 20160309
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In most cases, a playbook is a spiral bound notebook that outlines a strategy for a sport or a game. Whether for a football game, a video game, or even a board game, playbooks are all around us and when written properly provide immediate and easily understood direction. Playbooks can also provide general information; then it is up to the user of the playbook to tailor it to their individual needs.
Playbooks contain pictures, diagrams, quick references, definitions, and often step-by-step illustrations to explain certain parts. You can use playbooks to help you understand the entire game or you can pick and choose to focus on one element. The bottom line is that any playbook should be easy to read and to the point and contain little to no filler information.
The Cell Manufacturing Playbook is written for the Lean practitioner and facilitator. Like a football coach, a facilitator can use this playbook for quick reference and be able to convey what is needed easily. If for some reason the person leading the actual work cell implementation forgets a play, the playbook can be referenced.
You can follow page by page and use the playbook to facilitate a work cell implementation or you can go directly to certain topics and use it to help you implement that particular play. As a side note, I use the terms cell manufacturing and work cell as the same in definition.
At first glance, the improvement techniques within the Lean philosophy appear to provide a solution to many types of production-related issues. A powerful and effective improvement philosophy, Lean can prevent company failure or launch an organization into world-class operational excellence.
I have been a Lean practitioner for over 15 years and have been involved in many Lean transformations. It does not matter the industry you work in, the product you produce, or even the processes your company uses to transform something to a finished good, the problems and opportunities you face are the same as those of everyone else. Your company is not different or an exception. You, as a Lean practitioner, desire a smoother-running facility, reduced lead times, more capacity, improved productivity, flexible processes, usable floor space, reduced inventory, and so on. Organizations can implement Lean to make localized improvements or they can use Lean to transform the entire culture of the business. Regardless of your aspirations and goals for Lean, you and many other companies face another similar situation; getting out of what I call boardroom Lean, and moving toward implementation.
Have no illusions, Lean is about rolling your sleeves up, getting dirty and making change. True change comes on the production floor, in the maintenance shop, and in all the other areas of the organization and by implementing the concepts of Lean. Companies often become stuck in endless cycles of training and planning, with no implementation ever happening. This playbook is your guideline for implementation and is written for the pure Lean practitioner looking for a training tool and a guideline that can be used in the work area while improvements are conducted. There is no book, manual, or reference guide that provides color images and detailed step-by-step guidelines on how to properly implement a work cell. The implementation of cell manufacturing is a manually intensive action, and conducting work cell projects properly takes experience and direction. The Cell Manufacturing Playbook is not a traditional book, as you can probably see. It is not intended to be read like another Lean business book. The images in this playbook are from real work cell implementations, and I use a combination of short paragraphs and bulleted descriptions to walk you through how to effectively implement cell manufacturing.
Little or no time is wasted on high-level theory, although an introductory portion is dedicated to the 8 Wastes and Lean metrics. An understanding of wastes and metrics is needed to fully benefit from this playbook. I am not implying that high-level theory or business strategies lack value; they are highly valuable. This playbook is for implementation, so it will not contain filler information.
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