Removing the Barriers to Efficient Manufacturing: Real-World Applications of Lean Productivity

W. Edwards Deming’s central premise was that improvements in product quality would increase productivity, improve competitive position, and help ensure long-term survival. Point 12 of his landmark 14 Points for Management says that management’s job is to remove the barriers that keep people from taking pride in their work. That’s exactly what this book is about.

Shedding new light on Deming’s 14 Points, Removing the Barriers to Efficient Manufacturing: Real-World Applications of Lean Productivity outlines time-tested organizational structures and methods to help you reduce variability and deliver high-quality products consistently. It describes the financial losses that can occur as a result of variability and details the specific activities management must engage in to avoid these losses and ensure long-term success.

Instead of taking you on a "random walk," the book supplies each manufacturing group in your organization with straightforward directions for creating a smooth-running facility with reduced variability. It includes "work assignments" in each chapter that, if completed in the order presented, will guide you through the creation of the Model Vision for your manufacturing facility. It also:

• Covers key topics on working with people, including training and retraining
• Supplies pointers for working with unions
• Considers Single Minute Exchange of Die (SMED)
• Describes how to put it all together with action plans

The book includes a write up on Deming’s famous Red Bead Experiment as well as an introduction to statistical process control techniques in the appendices. Filled with real-world examples and a case study to illustrate essential concepts, the book arms you with the insight and common-sense approaches required to build on Deming’s fundamental principles and consistently deliver high-quality products that instill a sense of pride in your workforce.

About the Author

Daniel L. Ferguson received a BS (1967) and MS (1972) in mechanical engineering with a major in automatic controls from Clemson University. After receiving a direct commission in 1969, he served as a U.S. Army aircraft maintenance officer in Vietnam from 1970 to 1971.

Over his 40-year career in industry, he has held engineering and management positions in operations and maintenance with two Fortune 500 companies, between which he managed a polyester resins plant in the early 1980s for one of the major producers.

While serving as facilities and maintenance manager at a large manufacturing facility, his plant was tapped to be the pilot site for implementation of SAP plant maintenance for the corporation. As part of the SAP project team, he developed a number of systems and many plant structures that are still in use today. After a successful pilot, he was assigned to the SAP implementation team and was responsible for rollout at similar manufacturing facilities. Later, this responsibility was expanded to implementation at new acquisition companies. Considered an expert in this area, he was asked to resume this work on a consulting basis after retirement in 2008.

As a lifelong audiophile, he has written three books and a number of articles on loudspeakers and electronics. His current project of interest is development of a new orthopedic device to aid patients with Parkinson’s disease.