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Factory Physics (3rd Ed.)

Wallace J. Hopp, Mark L. Spearman

Factory Physics provides a science-based framework for understanding the fundamental principles governing manufacturing systems, enabling managers to improve performance by managing the relationships between variability, work-in-process, cycle time, and throughput.

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What it’s about

In a world of manufacturing management saturated with buzzwords and conflicting quick-fix solutions, 'Factory Physics' provides a clear, rational, and enduring approach to improving system performance. This book introduces a science of manufacturing, establishing fundamental laws that govern the behavior of production lines, much like the laws of physics govern the natural world. By understanding the core relationships between variability, work-in-process (WIP), cycle time, and throughput, readers learn to diagnose problems, identify leverage points, and design more effective systems. Moving beyond anecdotes and fads, 'Factory Physics' equips managers, engineers, and students with the intuition and analytical tools to manage buffers of inventory, capacity, and time, revealing how to achieve lean objectives without sacrificing performance and enabling the creation of a sustainable competitive advantage.

The through-line

Who it’s for
Manufacturing and supply chain managers, engineers, and students who are responsible for improving plant performance (cost, speed, quality, flexibility) and want to run efficient, predictable, and profitable operations.
The problem
Their manufacturing systems are complex, unpredictable, and underperforming, plagued by excessive inventory, long and variable cycle times, poor on-time delivery, and constant fire-fighting. They feel frustrated by the complexity, overwhelmed by a blizzard of contradictory management fads (MRP, JIT, Lean, Six Sigma), and lack a clear, unified framework to diagnose problems and make effective improvements.
The plan
  1. Review the lessons of historical manufacturing paradigms like MRP and JIT to understand their core insights and limitations.
  2. Master the fundamental principles of 'Factory Physics,' focusing on the crucial relationships between WIP, throughput, cycle time, and variability.
  3. Apply these principles to develop practical, integrated solutions for shop floor control, scheduling, capacity planning, and supply chain management.
The payoff
The reader becomes a master of their manufacturing domain, able to diagnose problems at their root, design efficient and predictable systems, and lead their organization to new levels of profitability and competitive advantage. · The reader's factory becomes a well-oiled machine characterized by low inventory, short cycle times, and reliable delivery, rather than a source of constant headaches and crises.

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