The 12 Principles of Manufacturing Excellence: A Leader's Guide to Achieving and Sustaining Excellence

CRC Press
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Explaining how to implement and sustain a top-down strategy for manufacturing excellence, The 12 Principles of Manufacturing Excellence: A Leader’s Guide to Achieving and Sustaining Excellence provides a comprehensive, proven approach for delivering world-class performance while also cultivating the right culture through leadership and mentoring.

Tapping into four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve vertical and horizontal alignment across your organization. He details a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function. Emphasizing the importance of using Lean and Six Sigma tools to improve your business, the book:

  • Integrates strategy and leadership development
  • Paves a path for culture change–Operator-Led Process Control (OLPC)—that prepares hourly employees to take control of their processes and prepares management to enable them to do it
  • Details an audit process for tracking progress and ensuring sustainability
  • Includes a CD with color versions of the images in the book as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can all be easily customized for the reader’s use

This resource-rich book will allow you to spell out leadership expectations and provide your employees and associates with a clear understanding of their individual roles. Helping you keep everyone in your organization focused during the quest towards sustainable manufacturing excellence, the accompanying CD supplies the tools you and your team will need to pursue it with passion, confidence, and urgency.

Listen to what Larry Fast has to say about his new book, The 12 Principles of Manufacturing Excellence.

Part One — Part Two

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About the author

Larry E. Fastis a 35 year veteran of the wire and cable industry and held senior management roles for 27 of those years. At Belden, where he spent his first 25 years, he was one of the youngest Plant Managers to ever take the helm at their flagship plant in Richmond, Indiana. At that time the plant employed over 1200 people in a building of nearly 800,000 square feet. In 1982 he became the senior manufacturing leader of the Electronic Division, a position that he held for 12 years. During that time he conceived and implemented a strategy for manufacturing excellence that substantially improved manufacturing quality, service and cost. He is regarded by some as "the father of manufacturing cells" in bulk cable operations in the industry. Prior to 1987, the only known application of cell technology had been in assembly operations such as cord sets and harnesses. He later started up a new cord set division for Belden and served as the General Manager for 4 years. This experience helped to round him into a stronger manufacturing leader where his passion for excellence continued with a strong customer bias.

In 1997, he joined General Cable Corporation to lead North American Operations as a member of the Corporate Leadership Team. At that time General Cable was known more as a "marketing company" that was frequently handicapped by a grossly underperforming group of manufacturing plants. After two years learning his new company''s culture, people, product groups, systems, etc. he was named the Senior Vice President of Operations. After a 1999 aquisition he had 28 plants reporting to him as well as Corporate Sourcing, Quality, Manufacturing Systems and Advanced Manufacturing Engineering. Later as plants were consolidated to less than 20, he was given expanded responsibility for the North American Supply Chain. This included the addition of Supply Chain Planning and Logistics and three regional distribution centers in addition to the 18 manufacturing facilities in the U.S., Canada and Mexico. These plants produce a diverse range of energy, communications, industrial and specialty wire and cable products.

His vision solidified with a strategy for manufacturing excellence that was embraced by General Cable''s Leadership Team and Board of Directors in 1999. By 2001 the first General Cable plant, (Malvern, Arkansas), won Top 25 recognition as an of Industry Week magazine''s finalist for "Best Plants" in North America. By 2009, General Cable manufacturing plants had been recognized for twenty-one awards honoring nine plants--six of which were named winners of the 10 "Best Plants" in North America. Fast''s plants were the first to achieve three Top 25 awards in consecutive years and only the second company to have twice had three Top 25 winners the same year in the 20 year history of the award. As evidence of the sustainability of the process, in 2009 there were three General Cable plants in the Top 20 for the third time. Also, the very first winner, Altoona, PA in 2003, came back in their first year of eligibility to compete and win for a second time! The six "Best Plants" winners represent the successful execution of the strategy in various cultures, union and non-union plants and in all three countries. The winners are: Altoona, PA, USA in 2003; Moose Jaw, Saskatchewan, Canada in 2005; Tetla, Tlaxcala, Mexico in 2006, and Indianapolis, IN, USA in 2007. Manchester, NH, USA joined this distinguished list in 2008. Altoona, PA, USA won for the second time in 2009 and Piedras Negras, Mexico joined the list of winners after having been a finalist in two prior attempts. The 2010 final results are not yet known at this writing but two plants have made the "Top 20" finalists list. They are Franklin, MA, USA for the second time and Lawrenceburg, KY, USA for the first time.

Fast holds a Bachelor of Science degree in Management and Administration from Indiana University and is a graduate from Earlham College''s Institute for Executive Growth. He also completed the Program for Management Development at the Harvard University School of Business in 1986.

Fast is a long time member of the Association for Manufacturing Excellence (AME), the Wire Association, and is a former member of the American Production and Inventory Control Society and the American Society for Quality. He also has served as a Section Chair for NEMA, the National Electrical Manufacturer''s Association. He has served on university advisory boards including Indiana University/Purdue at the I.U. East campus in Richmond, Indiana and the School of Applied Sciences at Miami University, Oxford, Ohio. From 2001 to 2007, he served on the Industry Advisory Board for the Tauber Manufacturing Institute at the University of Michigan in Ann Arbor. In 2009 he joined the Board of Directors, SE Region of AME. Since his retirement he has also joined the team of judges for Industry Week magazine''s "Best Plants in North America" competition.

Fast has spoken at various manufacturing excellence events such as Industry Week''s Best Plant''s Conference, Manufacturer "Live", AME Champions meeting and the international conference on Lean Manufacturing sponsored by Reliability World. He has also been published in National Productivity Review magazine for the turnaround story at Belden Wire and Cable and was featured in two October, 2006 articles in The Manufacturer and in Mexico Watch for the outstanding track record leading change at General Cable Corporation. Fast is now Founder & President of Pathways to Manufacturing Excellence, LLC, a consulting company based in Gainesville, GA.

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Additional Information

Publisher
CRC Press
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Published on
Sep 20, 2011
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Pages
266
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ISBN
9781466512870
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Language
English
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Genres
Business & Economics / Quality Control
Technology & Engineering / Engineering (General)
Technology & Engineering / Manufacturing
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Content Protection
This content is DRM protected.
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Read Aloud
Available on Android devices
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Eligible for Family Library

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In The Ice Cream Maker, Chowdhury uses a simple story to illustrate how businesses can instill quality into our culture and into every product we design, build, and market. The protagonist of the story is Peter Delvecchio, the manager of a regional ice cream company, who is determined to sell its ice cream to a flourishing national grocery chain, Natural Foods. In conversations with the Natural Foods manager, Peter learns how the extraordinarily successful retailer achieves its renowned high standard of excellence, both in the services it provides its customers and in the foods it manufactures and sells. Quality, he discovers, must be the mission of every employee; by learning to listen, enrich, and optimize, he can encourage and sustain the highest levels of quality in everything the company does.

Like Fish! and Who Moved My Cheese? The Ice Cream Maker offers an essential and universal lesson about one of industry's foremost challenges in a thoroughly engaging style. For managers and executives, small business owners and entrepreneurs, The Ice Cream Maker is a compelling, eye-opening guide to the most effective ways to achieve excellence and become industry leaders on the global stage.


From the Hardcover edition.
During her two decades at The New England Journal of Medicine, Dr. Marcia Angell had a front-row seat on the appalling spectacle of the pharmaceutical industry. She watched drug companies stray from their original mission of discovering and manufacturing useful drugs and instead become vast marketing machines with unprecedented control over their own fortunes. She saw them gain nearly limitless influence over medical research, education, and how doctors do their jobs. She sympathized as the American public, particularly the elderly, struggled and increasingly failed to meet spiraling prescription drug prices. Now, in this bold, hard-hitting new book, Dr. Angell exposes the shocking truth of what the pharmaceutical industry has become–and argues for essential, long-overdue change.

Currently Americans spend a staggering $200 billion each year on prescription drugs. As Dr. Angell powerfully demonstrates, claims that high drug prices are necessary to fund research and development are unfounded: The truth is that drug companies funnel the bulk of their resources into the marketing of products of dubious benefit. Meanwhile, as profits soar, the companies brazenly use their wealth and power to push their agenda through Congress, the FDA, and academic medical centers.

Zeroing in on hugely successful drugs like AZT (the first drug to treat HIV/AIDS), Taxol (the best-selling cancer drug in history), and the blockbuster allergy drug Claritin, Dr. Angell demonstrates exactly how new products are brought to market. Drug companies, she shows, routinely rely on publicly funded institutions for their basic research; they rig clinical trials to make their products look better than they are; and they use their legions of lawyers to stretch out government-granted exclusive marketing rights for years. They also flood the market with copycat drugs that cost a lot more than the drugs they mimic but are no more effective.

The American pharmaceutical industry needs to be saved, mainly from itself, and Dr. Angell proposes a program of vital reforms, which includes restoring impartiality to clinical research and severing the ties between drug companies and medical education. Written with fierce passion and substantiated with in-depth research, The Truth About the Drug Companies is a searing indictment of an industry that has spun out of control.
Following in the tradition of its bestselling predecessor, The 12 Principles of Manufacturing Excellence: A Lean Leader's Guide to Achieving and Sustaining Excellence, Second Edition outlines a comprehensive, proven process for delivering world-class performance while also cultivating the right culture through leadership, mentoring, and hourly associate involvement.

While most books on continuous improvement focus on specific tools and methods, this book details a top-down strategy and process that Lean leaders can use to implement and sustain manufacturing excellence. It outlines a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function.

This updated edition includes a new chapter on real stories about poor leadership at the top. Also featured are new and updated figures and exhibits. It contains chapters devoted to each principle of manufacturing excellence along with a chapter on each leader's role. Illustrating the importance of using Lean and Six Sigma tools to improve your business, the book:

Details a comprehensive approach for achieving and sustaining excellence—from board room strategy to shop floor execution Integrates strategy and leadership development Paves a path for culture change that prepares hourly employees to take control of their processes and prepares management to enable them to do it Details an audit process for identifying priorities for improvement and tracking progress and ensuring sustainability

Tapping into more than four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve both vertical and horizontal alignment across your organization. Like the previous edition, the book includes a CD with color versions of the images in the book, a manufacturing excellence reading list, and formulas for selected metrics.

The CD also includes a sample manufacturing excellence audit (a powerful tool to achieve and sustain the journey), a sample communications plan, a sample communications plan calendar, a sample training plan, and a new Project Prioritization worksheet—all of which can be easily customized to meet your organization’s specific needs.

Explaining how to implement and sustain a top-down strategy for manufacturing excellence, The 12 Principles of Manufacturing Excellence: A Leader’s Guide to Achieving and Sustaining Excellence provides a comprehensive, proven approach for delivering world-class performance while also cultivating the right culture through leadership and mentoring.

Tapping into four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve vertical and horizontal alignment across your organization. He details a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function. Emphasizing the importance of using Lean and Six Sigma tools to improve your business, the book:

Integrates strategy and leadership development Paves a path for culture change–Operator-Led Process Control (OLPC)—that prepares hourly employees to take control of their processes and prepares management to enable them to do it Details an audit process for tracking progress and ensuring sustainability Includes a CD with color versions of the images in the book as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can all be easily customized for the reader’s use

This resource-rich book will allow you to spell out leadership expectations and provide your employees and associates with a clear understanding of their individual roles. Helping you keep everyone in your organization focused during the quest towards sustainable manufacturing excellence, the accompanying CD supplies the tools you and your team will need to pursue it with passion, confidence, and urgency.

Listen to what Larry Fast has to say about his new book, The 12 Principles of Manufacturing Excellence.

Part One — Part Two

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