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Focused Manufacturing


Focused Manufacturing Professor Kleinberg Braulio Soto, Rob Morris, Evelyn Ozburn, Tiye Cort Focused Manufacturing Basic Concepts Characteristics Approach Basic ... – PowerPoint PPT presentation

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Title: Focused Manufacturing

Focused Manufacturing
  • Professor Kleinberg
  • Braulio Soto, Rob Morris, Evelyn Ozburn, Tiye Cort

Focused Manufacturing
  • Basic Concepts
  • Characteristics
  • Approach

Basic Concepts of a Focused Factory
  • Producing a lower cost is not the only way to
  • A company cannot perform well all the time
  • Simplicity and repetition create competence

Characteristics of a Focused Factory
  • Process Technologies Typically, unproven and
    uncertain technologies are limited to one per
    factory. Proven, mature technologies are limited
    to what their managers can easily
    handle, typically two or three.
  • Market Demands Quality, Price, lead times, and
    reliability specifications.
  • Product volumes comparable levels such as
    tooling, order quantities, materials handling
    techniques, and job contents, can be approached
    with a consistent philosophy. But what about the
    inevitable short runs, customer specials, and
    one-of-a-kind orders that every factory must
    handle? The answer usually is to segregate them.
  • Quality levels set approaches to neither
    over-specify nor over-control quality and
  • Manufacturing Tools limited to one or two at a

Manufacturing FocusA way to achieve it
  • Focus the whole manufacturing system on a
    limited task that is exactly represented by the
    companys competitive strategy and its actual
    technology and economics.

  • Center the factorys focus on appropriate
    competitive skills
  • Stay away from the tendency to increase staff and
    overhead in order to save on direct labor and
    capital investment
  • Each manufacturing unit should work on a limited
    task instead of a complex mix of opposing
    objectives, products and technologies.
  • Note
  • Others may also apply as company sees fit!

How can I achieve a focused plant?4 step process
  • Develop a specific, brief statement of corporate
    objectives and strategy
  • Should cover the next three to five years and
    top-management should be involved to (marketing,
    finance, control executives etc.)
  • Translate the statement into What it means to
  • What must the factory do well to meet and carry
    out the corporate strategy?
  • What will be the most difficult task we face?
  • If function is not strong where will we most
    likely fail?
  • Carefully examine each element of the production
  • How is it setup, organized, focused, and manned
  • What is it especially good at now?
  • How ought it be changed so it can carry out the
    key manufacturing task?
  • Reorganize the elements of structure to produce a
    congruent focus
  • This means organize it so that it is able to do
    the limited things that are most important to
    completing the manufacturing task.

Wickham Skinner
  • Considered the father of Manufacturing Strategy
  • Graduated from Yale
  • Emeritus professor at Harvard University
  • Wrote The Focused Factory

Basic Changes in Management of Manufacturing
  • Four Basic Changes
  • How can we compete?
  • Look at efficiency as the whole manufacturing
  • Each plant needs to learn to focus on a limited,
    concise, manageable set of products,
    technologies, volumes, and markets
  • Learn to structure basic manufacturing policies
    and supporting services so that they focus on one
    explicit manufacturing task instead of on many
    inconsistent, conflicting, implicit tasks
  • W. Skinner, The Focused Factory, Harvard
    Business Review June 1974

Reasons For Inconsistency
  • Professionals in each field attempt to achieve
    goals that are not corresponding with goals of
    other areas
  • Manufacturing tasks were never made specific
  • Inconsistencies never identified
  • Manufacturing task lightly changed while certain
    departments like operating and service stayed the
  • Market Product Proliferation

Alternative Approaches to Focusing Facilities
  • Based On
  • Products/Markets
  • Directed for specific customers or product groups
  • Processes
  • Puts products together based on similar processes
  • Manufacturings Strategic Task
  • Products are assigned to a specific unit based
    off OW Q
  • Task is consistent

Plant-within-a-Plant (PWP)
  • Divide existing plant into PWPs
  • Physically
  • Organizationally
  • Each PWP has its only facilities where it can
    focus on
  • Its specified manufacturing task
  • Use its own working style
  • Production control
  • Organizational structure

Results From Using a PWP
  • Volume Quality will not be mixed
  • Clear focus for worker training incentives
  • Resources are now shared
  • Equipment, engineering processes and materials
    handling are specialized as needed
  • Decreases focus regression
  • Smaller size

Forces That Make it Difficult to Focus
  • Marketing
  • Sales
  • Manufacturing
  • Accounting Finance
  • Corporate Forces

  • Questions?
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