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List of Figures xiv List of Tables xx About the Author xxii Preface xxiii Acknowledgments xxvii About the Companion Website xxviii 1 Throughput Concepts 1
1.1 Introduction to Throughput 1
1.2 Discussion of Manufacturing Throughput 7
1.3 Characteristics of Manufacturing Systems 14
1.4 Operational States of Production 21 2 System Performance Metrics 33
2.1 Performance Measurement 33
2.2 Manufacturing System OEE 43
2.3 Considerations on OEE 49
2.4 Further Discussion of KPIs 56 3 Bottleneck Identification and Buffer Analysis 71
3.1 Understanding of Bottleneck 71
3.2 Bottleneck Identification 76
3.3 Understanding of System Buffer 84
3.4 Buffer Analysis for Bottleneck Identification 89 4 Quality Management and Throughput 103
4.1 Quality Management 103
4.2 Cost Analysis of Quality 110
4.3 Quality in Production Throughput 117
4.4 Discussion of Improving Quality 124 5 Maintenance Management and Throughput 137
5.1 Maintenance Principles 137
5.2 Equipment Maintenance Strategies 147
5.3 Maintenance Performance Management 155
5.4 Consideration and Analysis in Maintenance 162 6 Throughput Enhancement Methodology 175
6.1 Approaches for Solving and Improving 175
6.2 Core Process for Throughput Enhancement 183
6.3 Particular Throughput Analysis 189
6.4 Project Proposal Management 195 7 Analysis and Design for Operational Availability 209
7.1 Introduction to System Design 209
7.2 Throughput Considerations in Design 216
7.3 Reliability-Based System Design 224
7.4 Additional Considerations in System Reliability 233 8 System Design for Throughput Assurance 245
8.1 Buffer Planning for Throughput 245
8.2 Analysis in Buffer Design 250
8.3 Throughput Capability Design 256
8.4 Additional Considerations 264 Appendix A Manufacturing KPIs 281 Appendix B Acronyms, Abbreviations, and Notations 291 Appendix C Answers to Exercises 297 Epilogue 299 Index 301