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| Acknowledgments | |
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| Preface | |
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| Manufacturing and Business Excellence | |
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| The Scene | |
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| The Players | |
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| Integrating the Manufacturing and Marketing Strategy | |
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| Becoming the Low-Cost Producer | |
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| Application of Increased Capacity | |
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| Beta's Beaver Creek Plant--RoNA vs. Uptime | |
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| A Model for Becoming the Low-Cost Producer | |
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| Measuring Losses from Ideal | |
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| Sample Calculation of Batch Plant OEE | |
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| Discussion of Sample Measurement | |
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| A Special Case--Beta's Dwale Plant | |
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| Hiding Behind Excess Capacity (The Hidden Plant) | |
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| Differences Between Batch and Continuous Manufacturers | |
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| Lean Manufacturing, Six Sigma, and Focused Factories | |
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| Summary | |
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| References | |
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| Benchmarks, Bottlenecks, and Best Practices | |
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| Benchmarking--Finding Benchmarks and Best Performers | |
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| Making the Comparison | |
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| Bottlenecks--A Dynamic View | |
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| Manufacturing Uptime Improvement Model | |
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| References | |
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| Integrating the Marketing and Manufacturing Strategies | |
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| Beta's Pracor Division | |
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| Market/Product Success Factors | |
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| Volume and Market Growth Analysis | |
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| Manufacturing Capability for Supporting Market/Volume Goals | |
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| Performance by Plant and by Product Line | |
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| The Plan | |
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| Revised Pricing Strategy | |
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| Plant Performance Requirements | |
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| Other Actions Required | |
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| The Expected Results | |
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| Effect of Product Mix on Manufacturing Performance | |
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| Beta's Leets Division--Rationalizing Customers and Markets | |
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| Summary | |
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| References | |
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| Plant Design and Capital Project Practices | |
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| The Design Process | |
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| Design Objectives | |
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| Key Questions | |
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| Operations and Maintenance Input | |
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| Estimating Life-Cycle Costs | |
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| Additional Case Histories | |
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| Payback Analysis--Too Simple and Too Expensive--Payback Is Hell! | |
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| Summary | |
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| References | |
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| Procurement Practices | |
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| A Model for Developing Strategic Alliances--Goose Creek Plant | |
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| Supplier Selection | |
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| Process for Improved Specifications for Equipment Reliability--Mossy Bottom Plant | |
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| Improving Supplier Reliability--A Case Study | |
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| Supply Chain Principles--A Strategic Approach | |
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| References | |
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| Stores/Parts Management Practices | |
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| What Are Stores? | |
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| The "Cost" of Stores | |
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| What Stores Are Needed--Kind and Quantity | |
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| Standardization | |
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| The Store | |
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| Contracting the Stores Function | |
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| Key Performance Indicators | |
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| Beta's Wheelwright Plant | |
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| Spare Parts Criticality Ranking Model | |
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| Summary | |
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| References | |
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| Installation Practices | |
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| Follow Existing Standards and Procedures | |
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| Verify and Use Appropriate Manufacturer Recommendations | |
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| Installation and Commissioning of Rotating Machinery | |
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| Flange and Joint Installation | |
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| Workshop Support | |
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| Housekeeping | |
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| Use of the Pre-Destruction Authorization | |
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| Summary | |
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| References | |
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| Operational Practices | |
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| Improving Operating Practices to Reduce Maintenance Costs | |
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| Consistency of Process Control | |
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| Control Loops | |
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| Process Conformance for Operational Excellence | |
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| Operator Basic Care | |
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| Establishing Operator Care/Ownership | |
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| Shift Handover Process | |
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| Production Planning | |
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| Advanced Process Control Methods | |
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| Summary | |
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| References | |
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| Maintenance Practices | |
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| Going from Reactive to Proactive | |
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| Beta's Repair Culture | |
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| Maintenance Practices | |
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| Preventive Maintenance | |
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| Predictive Maintenance | |
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| Beta's Current Predictive Maintenance Practices | |
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| Beta's Predictive Maintenance Deployment Plan | |
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| Proactive Maintenance | |
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| Focused Factories and Maintenance Practices: Centralized vs. Decentralized Maintenance | |
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| The Need for Integrating Preventive, Predictive, and Proactive Practices | |
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| Life Extension Program | |
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| Maintenance Practices and Safety Performance | |
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| Summary | |
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| References | |
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| Optimizing the Preventive Maintenance Process | |
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| First Things First | |
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| Creating Equipment Histories from "Scratch" | |
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| The Model | |
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| Some Examples | |
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| Case Histories | |
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| Mechanical Integrity | |
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| Summary | |
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| References | |
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| Implementing a Computerized Maintenance Management System | |
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| Case History | |
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| Reference | |
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| Effective Use of Contractors in a Manufacturing Plant | |
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| The Reliability Improvement Program | |
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| Consolidating Maintenance Contractors | |
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| What Happened? | |
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| Lessons Learned | |
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| Best Use of Contractors | |
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| Summary | |
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| References | |
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| Total Productive and Reliability-Centered Maintenance | |
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| Total Productive Maintenance Principles--TPM | |
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| Reliability-Centered Maintenance Principles--RCM | |
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| Case Study | |
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| Some Additional Benefits | |
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| Summary | |
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| References | |
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| Implementation of Reliability Processes | |
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| Whamadyne's Journey to Manufacturing Excellence | |
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| Whamadyne's Reliability Improvement Plan | |
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| Results--World-Class Performance | |
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| References | |
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| Leadership and Organizational Behavior and Structure | |
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| Leadership | |
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| Organizational Issues | |
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| Empowerment | |
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| Empowerment as a Disabler | |
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| The Reliability Process--A Better Way | |
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| Reliability Improvement Teams | |
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| Organizational Structure | |
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| Mission Statements | |
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| Communication of Performance Expectations | |
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| Implementing Reliability and Manufacturing Excellence in a Union or Non-Union Plant | |
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| Compensation | |
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| Summary | |
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| References | |
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| Training | |
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| The Strategic Training Plan | |
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| Boss as Trainer | |
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| Training Versus Learning | |
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| Training for Pay | |
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| Training in Appropriate Methodologies | |
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| Multi-skilling and Cross-functional Training | |
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| Intellectual Capital | |
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| Closing | |
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| References | |
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| Performance Measurement | |
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| Return on Net Assets or Return on Replacement Value | |
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| Plant Age and Reliability | |
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| Measure for Weaknesses | |
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| References | |
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| Epilogue | |
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| Beta's 10-Point Plan | |
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| World-Class Manufacturing: A Review of Several Key Success Factors | |
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| Reliability Manager/Engineer Job Description | |
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| Index | |