Is it possible to be repetitive and flexible-at the same time? Using proven examples and quantifiable evidence, Lean RFS (Repetitive Flexible Supply): Putting the Pieces Together demonstrates that repetitive flexible supply (RfS) is not only possible, but that its implementation can help you reach a new level of improved performance in manufacturing and across your entire supply chain.
Winner of a 2013 Shingo Research and Professional Publication Award, this book is unique in that it clearly spells out the theory and practice originally published in the Shingo Prize winner, Breaking Through to Flow, with actual stories of Kimberly-Clark's experience in using them over the years with great success. These stories provide a real feel of how this learning-by-doing journey led to "aha!" moments for those involved.
The book also explains why most planning systems in use today will result in a different plan every time, and that these plan changes are actually the cause of the fire fighting that is endemic in most companies.
Ian Glenday started his Lean journey as a microbiologist running a plant producing enzymes from deep-culture fermentation of bacteria. It was here that Ian first began developing RfS concepts and principles for application in process industries. After taking time out to gain an MBA from Bradford Business School in the UK, Ian joined the manufacturer Reckitt & Colman, where he led an MRPII project To Class A status in the company's pharmaceutical division. This experience offered Ian a valuable lesson in understanding why applying batch logic in MRP can cause problems. Ian then moved to Reckitt & Colman's household and toiletries division, where he initiated and helped implement a pan-European supply chain strategy based on the Lean concept of "every product every cycle," before joining Colman's of Norwich as head of policy deployment, responsible for applying Lean/RfS thinking across the entire company. Ian currently divides his time between working with Professor Dan Jones at the Lean Enterprise Academy, UK, where he is a senior fellow, and helping businesses around the world make their own Lean transformations through his company Repetitive flexible Supply Ltd. Rick Sather is vice president, customer supply chain, for Kimberly-Clark Corporation's North America Consumer Products Division. In this role, he is responsible for service and efficient product flow from the end of manufacturing through the customer's retail shelf. Originally from Wisconsin, Rick received a BS degree in industrial technology from the University of Wisconsin-Stout in 1985, and for the past twenty-seven years has worked in a wide range of supply chain roles. Rick's Lean journey began in 2005 when he first connected with Ian and began implementing Lean/RfS at Kimberly-Clark. Learning and applying Lean/RfS in direct-line roles has enabled Rick to establish a problem-solving culture focused on delivering exceptional outcomes for people, customers, and shareholders alike.
Twenty-Five Years at Kimberly-Clark Does This Sound Familiar? Do You Face This? Have You Done This? Have You Experienced This? Searching for a Step Change Summary of Chapter 1 The Fundamentals of Lean/RfS A Brief History The Key Components of Lean/RfS Batch Logic Issue Alternative Logic of Flow Lean and Leveled Production Economies of Repetition Glenday Sieve Central Limit Theory and Buffer Tanks Rockbusting Summary of Chapter 2 How It Can Be Some Examples and Anecdotes Impact on Behavior Impact on Problem Solving Impact on Results Green and Beige People Policy Deployment Squash Quosh Stages in a Lean Transformation Summary of Chapter 3 The Lean/RfS Corner Pieces Changing from Batch to Flow Batch Logic Is Bad What Is "Responsiveness"? Calculating the Schedule Buffer Tank Calculation and Rules A Lesson in Setting Accurate Buffer Tank Limits Integrating Lean/RfS into Existing Processes and Systems Some Results Summary of Chapter 4 The Lean/RfS Straight Edges RfS-Dependent Straight Edges Material-and Other-Flows Blues and Reds Lean/RfS Product Costing Applying RfS Principles Across the Business Other Straight Edges Supporting Lean/RfS in the Business Policy or Strategy Deployment? Strategy Deployment Key Aspects of Strategy Deployment That Helped Achieve a Transformation in the Way KC Operated The Difference between Traditional Strategic Planning versus Strategy Deployment Lean Leadership Four Rules of Lean Summary of Chapter 5 The Lean/RfS Center Pieces Rockbusting Schedule Breaks How to Measure Conformance to Plan Time versus Quantity Niggles Summary of Chapter 6 Putting the Pieces Together Timeline for the Stages in a Lean Transformation Opportunities for Kimberly-Clark The 5-Day Rapid Implementation Approach Stretching Lean/RfS Forces against Flow Lean/RfS Fundamental Beliefs Summary of Chapter 7 Glossary Recommended Reading Appendix A Index