Editorial Review:
Creating Mixed Model Value Streams is a hands-on primer for those seeking to implement lean in complex environments. When faced with complex or unique situations, companies often disregard lean principles and fall back on previous practices. In this book, Kevin Duggan describes the lean techniques that can be used when faced with difficult situations such as high product mix, scheduling problems, shared resources, and unstable customer demand. This book will give mangers the knowledge to guide their companies through these tough obstacles and to attain positive bottom line results! The author uses a step-by-step approach, illustrated through a case study based on actual experience, to go beyond the basics of value stream mapping and show how to create future states in the real manufacturing world of multiple products, varying cycle times, and changing demand. The book includes a CD-ROM featuring useful spreadsheets for sorting products into families and calculating equipment needs. Comprehensive and down-to-earth, Creating Mixed Model Value Streams provides the details and new techniques for implementing lean in the complex environment that manufacturers face on their own shop floors. CD-ROM includes: Spreadsheet and tutorial for sorting products into families Spreadsheets for calculating equipment required and for determining the interval for EPEI (Every Part Every Interval) Samples of visual method sheets for standard work Case study value stream maps and mapping icons
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Customer Reviews
Average Customer Rating: 
Great read, glosses over detail  2008-04-10
I have to agree with other reviewers. The math is dead simple. And the transition from batch to flow will re-invent your business.
Where to book fell down for me was in the examples given. If i worked in a shop which only produced a small list of parts and very little process variation i would be done implementing by now.
Where a small business may fall most large facilities/organizations do not. Again, great way to approach changing the way your business runs but without some serious data mining and statistical skills you will end up right where you started.
Accessible Exposition of Principles but the Devil's in the Details 2006-09-23
In this very good book author Kevin Duggan describes an approach to implementing lean manufacturing in challenging environments characterized by a high degree of variety, shared resources, and lumpy demand. All too often in such situations, practitioners conclude that lean principles can be applied incompletely or not at all. Significant missed process improvement opportunities follow from this foundational misunderstanding.
Duggan develops his material using as a case study the hypothetical EMC Supply Company. Value stream mapping is used throughout the book to depict the current scenario and the various improvements to achieve the desired future state.
The author starts at the very beginning, with a discussion of how the proper definition of product families is critical to the creation of flow in high mix plants. He goes on to introduce the concepts of takt time and the pacemaker operation for the process. From there the discussion moves to the balancing of operations, presentation of materials at the point of use, scheduling the work, and dealing with variation in customer demand.
These concepts are applied by the EMC implementation team and are illustrated with an evolving series of value stream maps. As a result the presentation has a "real world" feel to it that should encourage application of the principles.
One significant caveat needs however to be mentioned. Successful implementation is about pressing through countless details in every situation. Duggan draws attention to this in various places writing for example, "Material presentation for a high mix of products will take some creativity and planning. This is an area where we will have to sweat the details".
In fact, in my experience as a lean implementer, the details need to be sweated at every turn. The concepts may be simple, elegant, and often self evident, but putting them into action requires an almost obsessive attention to a myriad of practical intricacies.
For those committed to making this effort the results will be impressive. This book can help make it happen.
lean for Mom and Pop job shops.  2005-01-16
Value stream mapping and lean "nuts and bolts" for high variety - low quantity products. This book walks the reader through the process of setting up a high variety flow. I am no lean expert by an stretch of the imagination, but found this book to be extremely helpful in understanding and implementing the technique of flow.
The writing is very clear and concise. Graphics show clearly the subject being discussed.
I suggest reading Learning to See first to understand how to create value stream maps, then apply those learned skills to the floor using Creating Mixed Model Value Streams.
This book should be a required core course in the lean planned program of study. But remember there is no graduation, only life long learning.
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