Lean for the Process Industries

Dealing with Complexity, Second Edition

By: Peter L. King

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Hardcover | 19 June 2019 | Edition Number 2

At a Glance

Hardcover
374 Pages

Edition Type
New edition

Dimensions(cm)
23.39 x 15.6 x 2.24

Hardcover

$197.75

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Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others.

Drawing on more than 40 years of application experience at one of the world's largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition:

Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations.
Explains how to adapt value stream mapping for process operations.
Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated.
Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations.
Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors

Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition.

While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful.

Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

Industry Reviews

King provides an excellent, comprehensive guide for applying Lean to the Process industry. Not only is the book a great guide, but he captures the key pitfalls and ways to avoid on a journey to establish a sustainable Lean system. A great reference for all Lean efforts.
-- David M. Rurak, Chief Supply Chain Officer, W.L. Gore & Associates

The first edition of this book was a stand-out text, breaking down the myths of Lean in the Process industry. It's great to see an updated version to push the knowledge and understanding further - a must read.
-- Paul Griffiths, Senior Lean Manufacturing Manager EMEA, GE Healthcare

This book is a must read for Lean practitioners working in food, chemicals and pharma industries. The first edition allowed us to solve the mystery of how to adapt our eVSM software, which had been very successful in mapping discrete parts manufacturing, to illustrate the complexities of process operations. Peter's knowledge of this industry over more than four decades comes through clearly from the pages.-- Dilesh Patel, CEO, The eVSM Group

I am very impressed with the writing style - simple, clear, to the point - so it is easy to read. The pace is right - sufficient detail balanced with a natural flow. [Readers feel they] are making progress in every paragraph - which is rare to experience in these kinds of books.

-- Noel Peberdy, President, Zinata Consulting

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