Liquid Lean: Developing Lean Culture in the Process Industries

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CRC Press, Feb 24, 2010 - Business & Economics - 346 pages
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
 

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Contents

Foreword
Lean Enterprise Thinking
Policy Deployment
A Strategic View of Manufacturing
Strategic Alignment and Necessary
The Role of Communication in Achieving
Deploying Strategic Intent
Framework for Action
Basic Statistical Concepts
Process Improvement Using Statistical
The Process
Using SPC at the Frontline in a Process
Process Is Nearly Normal
Notes
Equipment Reliability and Operator Care
Keep the Equipment Clean

External Team Conversations
Translating NASCAR Success to
Equipment
The Five Key Components of SMED
Modification of RateLimiting Internal
Modification of the Work Team
Preparing for Events and Sustaining
Operational Planning to Improve
The Four Components of FSVV Practice
FSVV Inventory Policy
Assessment and Improvement of Other
Statistical Quality Improvement
Advanced Techniques
Creating
The Elements of Engagement
Time to Make Improvements
Engage Frontline Teams
Notes
Finding the Right Management Tool
Leaders
Developing Highly Competent People
Initiating and Sustaining
Index
Copyright

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About the author (2010)

Raymond C. Floyd is senior vice president of Suncor Energy. Prior to joining Suncor, Ray retired from Exxon Mobil, where he spent more than 20 years and where he most recently served as global manager of manufacturing services. Previously, he was with General Motors for more than 10 years. Ray is generally recognized as one of North America‘searly adopters of lean manufacturing and is among the very first worldwide to adapt lean technologies for use in the chemical and process industries.

Following the practices described in this book, Ray led the first chemical business to receive the Shingo Prize and has led two separate businesses that have been designated as one ofAmerica‘s ten best plants by IndustryWeek magazine. Ray is the only person to lead businesses in both chemical and mechanical manufacturing to receive that designation. As site manager for Exxon‘s massive Baytown chemical plant, Ray led the team that was designated asbest maintenance organization in large industry by Maintenance Technology magazine. Ray received the Andersen Consulting award forexcellence in managing the human side of change.

Ray has degrees in chemical engineering, business administration, and law. He is professionally licensed as an engineer, attorney-at-law, and patent attorney. He has also received international senior executive development at the Institute for International Studies and Training in Japan and the Institute for Management Development in Switzerland. Ray was appointed by President Reagan to represent the United States at the Japan Business Study Program as a guest of Japan‘s Ministry of International Trade and Industry. Ray‘s wife, Marsha, is also an attorney-at-law. Ray and Marsha have two daughters, who are both physicians, and five grandchildren.

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