As someone responsible for getting-and keeping-your manufacturing facility on track, do you ever ask yourself: Why do we always seem to be in a state of mass confusion? Is it possible to ship the product on time? How do we meet our customers' demands without promising too much and delivering too little? Why are costs continually rising, and what can be done to curb them? Written by James Correll and Norris Edson, two principals with Oliver Wight, LLC, this comprehensive resource, now completely revised and expanded, provides the answers you need for Gaining Control of your operation.

To illustrate the essential elements that go into the smooth and effective running of a manufacturing facility, the authors take you inside the fictitious Hayes Tractor Company. By following its manager, Brian Miller, you'll observe all-too-recognizable problems-from meeting orders in a timely fashion to securing the right people and parts -learn what can be done to solve them, then apply the solutions to your own situation.

Gaining Control shows you the detailed steps necessary to gain control by matching plant capacity to production needs using a combination of tools, such as Just-in-Time, MRP II, and finite scheduling, as well as new innovative trends like lean and agile manufacturing-all of which can be used to obtain confusion-free, efficient operations in a single or multiplant environment.

Packed with sample calculations, helpful charts, and useful tables, here's where you'll find complete information on:

* Constructing routings and work centers

* Mastering dispatching and scheduling

* Controlling work flow

* Scheduling to capacity constraints

* Applying rough-cutcapacity planning

* Continuous improvement

By implementing the tools and techniques shown in Gaining Control, you'll know exactly what your plans are and have the confidence that you'll hit them on target.

Proven strategies for Gaining Control of your manufacturing facility

Throughout our professional careers . . . we have been troubled by the apparent inability of manufacturing departments to get control of their operations. . . . Our objective in writing this book is to help you understand what you have to do to get the real benefit from MRP II and Lean Manufacturing. The answer is in gaining control of the factory floor, often referred to as 'closing the loop, ' and this book shows you how. -from the Introduction

Now revised and expanded, Gaining Control addresses the many questions and potential problems that can arise when running a manufacturing facility. Written by two experts in the field, it shows managers how to gain control by matching plant capacity to production needs by implementing a combination of tools, such as Just-in-Time and MRP II. Along with new material on finite scheduling, this Second Edition provides complete coverage of current manufacturing trends, including lean and agile manufacturing.

This book shows managers how to gain control of a manufacturing facility by matching plant capacity to production needs. In this meticulously detailed book, the authors reveal how a combination of tools such as just-in-time, MRP II, lean manufacturing, and finite scheduling can be used to obtain confusion-free, efficient operations in a single or multi-plant environment.

Anyone will tell you that the business world is only getting more competitive and complicated. So how do you manage your manufacturing facility and maintain optimum throughput?

James Correll and Kevin Herbert will show you how in this new edition of Gaining Control. This fully updated revision provides best practices for optimizing control of manufacturing processes to meet business objectives. Always reliable and more complete than ever, this easy-to-read resource offers real solutions and proven methodologies for achieving measurable improvements in effectiveness and employee engagement and morale.

Now in its third edition, Gaining Control addresses the many changes that have occurred since its last revision, including advanced planning systems, outsourcing, and new computer-based technologies. Written by the leading experts in the field, this essential guide will help you match your production facility's capacity to optimize supply, eliminate uncertainty in your staff, and gain control of your factory.

The business world is more challenging than ever. New technologies present new opportunities and the increasing demands for responsiveness and flexibility mean that manufacturing must have levels of control never imagined twenty-five years ago. In attempting to face up to all these challenges, it is often difficult to know where to begin, and this can lead to employee confusion and underperformance. Gaining Control helps you get control of manufacturing facilities and achieve increased output by retaking command with expert advice and down-to-earth writing from James Correll and Kevin Herbert, two prominent consultants from the Oliver Wight company.

Gaining Control takes you inside the Hayes Tractor Company, a fictitious company but one with all too familiar characteristics and situations. The authors expose the conditions that are causing the company to fail and miss production deadlines, leading to employee morale and discipline problems. Then, they reveal the proven and effective strategies that Oliver Wight uses to help businesses with these issues gain control of their production resources for more effective deployment—whether the resources are people, processes, or machines. Following the example of Hayes, you'll learn how to apply these best practices to your own operation, leading to better control, higher efficiency, and more satisfied employees and customers.

This fully up-to-date new edition includes twenty-four new methods, concepts, and technological advances introduced since publication of the last edition. The authors explore methodologies like Finite Capacity Scheduling and Advanced Planning and Scheduling, pointing out pitfalls and potentialities and showing you how to implement planning and scheduling enhancements across the entire business. A complete guide to manufacturing effectiveness, the book also offers expert coverage of topics such as advanced planning systems, and lean and computer-based scheduling.

Gaining Control will help you close the loop in your goals to consistently deliver on time, maximize efficiency, and reduce lead times. Combining new software, technologies, and processes with tried-and-true methods, this revised edition of a classic text will help you take command of your facilities and improve all aspects of performance.

JAMES G. CORRELLis Prin-cipal of Oliver Wight Americas, Inc. Certified by the Association for Operations Management (APICS) in production and in-ventory management at the Fellow level, he has presented several papers at APICS international conferences.

KEVIN HERBERThas been an Oliver Wight Associate since 1998. He was formerly Eastman Kodak's director of supply chain management-logistics for Europe, Africa, and the Middle East. He is a member of APICS, and has taught students how to achieve qualification for the APICS Diploma in Production and Inventory Management (DPIM).

Acknowledgments.

Introduction.

Cast of Characters.

One. Out of Control.

Two. Gaining Knowledge.

Three. Constructing Routings and WorkCenters.

Four. Mastering Dispatching and Scheduling.

Five. Understanding Detail Capacity Planning.

Six. Controlling the Flow of Work.

Seven. Applying Rough-Cut Capacity Planning.

Eight. Joining Forces.

Nine. Scheduling to Capacity Constraints.

Ten. Eliminating Waste and Variability.

Eleven. Advanced Planning, Optimizing, & Scheduling.

Twelve. Moving Ahead.

Index.