15 Articles Overview Seminars Consulting Results books Clients Credentials Inventory Reduction offahoring

Two major new articles on scalability at: 

Scalability for Major Programs and 

Scalable Innovation as Fast as Needed

 

If you don't know who your customers are going to be
or what they want, then you need  to 
Build-to-Order everything

If you don't have enough NPD resources  and do not
 know which customers to design for, then
 design broad Product Families that can all be Built t0-Order.
(see  Section  4.7  in the   2020  DFM  book)
 

HOW  TO  IMPLEMENT  BUILD-TO-ORDER  with self-supporting  steps:


Eliminate Setup/Changeovers, which will save all that time, cost  avoid wasting machine capacity, and enable the elimination of inventory (next).

Eliminating Inventory while improving order fulfillment

Pull parts into production on-demand instead of forecasts  → purchase-orders → waiting → inspecting → parts-inventory → kitting for batch production, which usually goes into inventory.
 

HOW   FLEXIBILITY   CAN   ADAPT y

In this day and age, combining all of the above can enable organizations to be flexible and quickly adapt with respect to enable factories to adapt to challenges to workforce availability by the following methodologies:

1) Design for Manufacturability teaches how to minimize skill demands by design. The DFM site page on Manufacturability Research shows how do this in research. See https://www.design4manufacturability.com/research.htm , which research functions can apply immediately.

.The cost/steel reduction workshop shows how to replace high-skill-demand weldments with rigid and precise assemblies of automated CNC machined parts. See:  https://www.design4manufacturability.com/steel-reduction-workshop.htm 

2) Concurrent Engineering shows how to cut in half the resource-hours needed to develop products AND cut in half the hours to build those products AND cut in half the usual indirect labor. See the white-paper: " Concurrent Engineering for Challenging Products" at:  https://www.design4manufacturability.com/concurrent-engineering.htm 

-3) Prioritization focused on the highest return of resources invested by avoiding "taking all orders" with Product Line Rationalization. 

4) Lean Production can "double labor productivity  all the way through the system (for direct, managerial, and technical workers, from raw materials to delivered product) - says Womack & Jones in "Lean Thinking" on page 27.

 

How Build-to-Order Works  shows two perspective (3D)  plant layouts for Electronics (fig.1) and Fabricated Parts or Products (Fig 2)
 

Build-to-Order & Mass Customization Webinar: Customized to your products, cab reach unlimited attendees wherever they are.  Four afternoon on sessions allow everyone to get, at least, half day f work between sessions.
 

Upcoming public  webinar   on Design  for  Lean & Build-to-Order 

2-day webinar: Sept 20-23 from 1-5 PM EST Complete  description at:

 https://qualitysupportgroup.com/design-for-lean-manufacturing/ 
Lean Champions and implementers  can also 
bring  decision-maker and  Managers. 
A 15% discount is available (on request) for 2 or more people from the same company

Timely articles: Strategies for recessions and getting back to work:

The Case Against Offshoring; and What to Replace it with

(Companion article on  hidden  offshorIng costs)

 How BTO can Help Design Half-Cost Products

      Executive Overviews  on build-to-Order & Mass Customization

 Strategy http://www.design4manufacturability.com/strategy.htm

 

New 2021 article: Design to scale up millions When Needed
without supply shortages or production bottle-necks

If busy, go to: http://design4manufacturability.com/scalability.htm 
 If busy go to: http://halfcostproducts.com/Scalability.htm 

 

Read the ultimate case-study of a greenfield plant that was based on these principle
s
 

Build-to-Order and Mass Customization represent a viable business model that offers an unbeatable combination of responsiveness, cost, and customer satisfaction.  Click on image for details of book on "Build-to-Order & Mass Customization" of click "books" icon above.

Build-to-Order Read Recession Strategies on ways BTO can help immediately.                                         

Build to order enables the manufacture of any quantity of standard products on-demand without forecasts, inventory, or purchasing delays with unique Spontaneous Build-to-Order methodologies.  Customized in-house seminars and consulting show how to implement BTO.

Free BTO book, signed by the author, for US callers.  Just call Dr. Anderson at 805-924-0100 (after 8:30 am Pacific) for a free assessment of how much these methodologies can help your company

Mass Customization

Mass Customization enables manufacturers to build products on-demand that are mass customized for niche markets, various countries, or individual customers with Mass Customization techniques.  In-house seminars shows how to implement mass customization.

Lean Production, Supply Chain Management, Product Portfolio Planning, Part Standardization

Implement Lean Production, flow production, flexible manufacturing, setup/batch/inventory reduction, and the ultimate in Supply Chain Management where parts are build-to-order based on assembly "pull signals" or automatically resupplied by kanban. Simplify supply chains optimal outsourcing decisions and with:

(1) Product Line Rationalization to eliminate or outsource older, low-volume products with the most part variety and

(2) Part Standardization and raw material standardization.

Cost Reduction & Design for Manufacturability

Cut product costs in half using the above techniques to reduce overhead costs and DFM to achieve the lowest fabrication and assembly cost with the highest quality by design based on a forthcoming book.

On-Demand Production

Use Build-to-Order and mass customization to build products on-demand to satisfy industrial customers, mail order, or rapid on-demand replenishment of stores for Lean Retailing resupply.

A VIABLE   BUSINESS   MODEL

Build-to-order and mass customization represent a viable business model that offers an unbeatable combination of responsiveness, cost, and products that customers want when they want them. It enables companies to build any product - standard or custom - on demand without forecasts, batches, inventory, or working capital.  Read the article Recession Strategies to find out how BTO can immediately lower costs, improve profits, and free valuable resources to improve operations, quality, and product development, without major capital costs.

Build-to-order  and mass customization companies enjoy substantial cost advantages from eliminating inventory, forecasting, expediting, kitting, setup, and inefficient fire-drill efforts to customize products. BTO results in more efficient utilization of people, machinery, and floor space.

Build-to-order and mass customization substantially simplifies supply chains not just "managing" them to the point where parts and materials can be spontaneously pulled into production without forecasts, MRP, purchasing, waiting, or warehousing.

Build-to-order and mass customization is the best way to resupply parts to OEMs or products to "lean retail" stores who demand rapid replenishment, low cost, and high order fulfillment rates without the classic inventory dilemma: too little inventory saves cost but increases out-of-stocks, missed sales, expediting, and disappointed customers; too much inventory adds carrying costs and costly obsolescence.

Build to Order and mass customization companies can grow sales and profits by expanding sales of standard products in addition to customized, derivative, and niche market products, while avoiding the commodity trap. BTO companies are the first to market with new technologies since distribution "pipelines" do not have to be emptied first.

The mass customization capabilities of build-to-order can quickly and efficiently customize products for niche markets, countries, regions, industries, and individual customers.

 

New Article on strategy http://www.design4manufacturability.com/strategy.htm

 

Would you like to  enquire further?

For a secure form, go to: form  at  the secure site: https;//design4manufacturability.com

I am interested in customized in-house seminars or workshops on Build-to-Order & Mass Customization.*

I am interested custom remote BTO* webinars at 1/3 less cost, no class limit, and flexible scheduling

I am interested in customized in-house seminars or workshops on Design for Manufacturability.**

I am interested custom remote DFM** webinars at 1/3 less cost, no class limit, and flexible scheduling

Please notify me of any future public seminars or webinars on Build-to-Order & Mass Customization

        * To preview principles of BTO & Mass Customization, read the the 510 page book with the a 60 page Exec Summary
      **  To preview principles of DFM & Concurrent Engineering, read the definitive work on the subject

Name

Title/Position

Company/Division

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e-mail address

Type of products
 

Web page URL of product that needs the most improvement
 

Number of different products (SKUs)


Challenges, goals, and opportunities (check all that apply)

Minimizing product cost
Minimizing  product development cost
Fastest time to stable production
Designing in the best quality and reliability right-the-first-time
Fastest build time and throughput time
Designing for Lean Production, Build-to-Order, and Mass Customization
Assured availability of parts, materials, and products
More effective product development process
Growth and ability to meet peak demand
Other challenges, goals, and opportunities:

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Call Dr. Anderson at 1-805-924-0100  (Pacific time) to discuss implementing these techniques or e-mail him at anderson@build-to-order-consulting.com with your name, title, company, phone, types of products, and needs/opportunities.

 

Cost reduction - Reduce your manufacturing cost. Our cost reduction program shows 8 strategies on how to significantly reduce cost. Cost reduction can result in significant product cost saving.

ustomization, build to order, flow, lean production, JIT & standardization: leading-edge consulting, seminars, articles & books on the ultimate in supply chain management, cost & agility.

Mass customization and build to order - articles, books, consulting and seminars. Simplify your supply chain, extend lean production to build mass-customized or standard products on-demand.

 

Dr. David M. Anderson, P.E.,  fASME, CMC
Management Consultant
Build-to-Order Consulting
phone: 1-805-924-0100
fax: 1-805-924-0200
e-mail: anderson@build-to-order-consulting.com
 

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Copyright 2021 by David M. Anderson

Mass customization, build to order, flow, lean production, JIT & standardization: leading-edge consulting, seminars, articles & books on the ultimate in supply chain management, cost & agility.

Mass customization and build to order - articles, books, consulting and seminars. Simplify your supply chain, extend lean production to build mass-customized or standard products on-demand.