Optimizing Factory Performance

Optimizing Factory Performance: Cost-Effective Ways to Achieve Significant and Sustainable Improvement


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TQM, Reengineering, Theory of Constraints, JIT, Six Sigma, Lean Manufacturing . . .

These are just some of the methods that, over the past five decades, have promised to transform any manufacturing firm into a lean, mean, moneymaking machine. While each incorporates certain fundamental truths, strengths, and benefits, they are not panaceas. Nor do they necessarily provide much-needed insight into the science that underlies factory performance.

James Ignizio, Ph.D., an internationally recognized performance optimization expert, believes that only a balanced approach will provide the significant and sustainable improvement required of firms who will survive and prosper in the twenty-first century.

In this breakthrough guide, Dr. Ignizio picks up where such concepts as Six Sigma and Lean Manufacturing leave off to provide you with a holistic, three-dimensional approach to mastering the art and science of manufacturing.

Focusing on the three primary enemies of factory performance—complexity, variability, and lackluster leadership—Optimizing Factory Performance cuts to the heart of the problem of less-than-world-class performance and demonstrates how those enemies manifest themselves in companies across manufacturing sectors. Ignizio also explores the insidious effect company politics and flagging commitment to manufacturing performance have on competitiveness.

Emphasizing the all-important, often overlooked third dimension of manufacturing—factory protocols—Ignizio describes the types of strategicand tactical changes to physical plant and operating procedures any company can make to achieve performance improvements. In addition, he arms you with powerful, original metrics for measuring and comparing factory performance, as well as a set of interactive simulation models, available online at www.mhprofessional.com/ignizio.

Running throughout the book is an often amusing, always instructive account of the fictional high-tech firm, Muddle, Inc., which helps support the concepts discussed in the real world of manufacturing, while reinforcing key lessons learned.

Read Optimizing Factory Performance and find out how to transform your organization into the kind of fast, agile manufacturer that delivers the right products to the right customers at the right time— every time.


Author comments

James P. Ignizio, Ph.D., is founder and principal of FactoryAnalyst.com, a consulting practice with clients on four continents, including those in the semiconductor and solar cell manufacturing sectors. Dr. Ignizio is the author of nine books and over 350 technical papers, including more than 150 articles in peer-reviewed professional journals. He is a Fellow of the Institute of Industrial Engineering, a Fellow of the British Operational Research Society, and a Fellow of the World Academy of Productivity Science. Over the past 30 years, he has presented short courses and seminars on manufacturing, operations research, and industrial engineering to thousands of professionals in industry and government.

Back cover copy


Boost factory performance and transform your company into a world-class competitor

You can dramatically improve factory performance, decrease cycle time, increase capacity, and cut costs, while expanding your profits and market share. You won’t need to invest in new equipment and technologies, make sweeping personnel cuts, or relocate your facilities to far-flung locales around the globe. Best of all, these improvements will be sustainable.

Sound too good to be true? You won’t think so once you’ve readOptimizing Factory Performance.

Unlike TQM, Six Sigma, Lean Manufacturing, and similar “remedies,” which offer only partial solutions to the problem of manufacturing inefficiency, the methodology outlined in this book is firmly rooted in the real world of manufacturing and based on sound science. Dr. James Ignizio offers a balanced, three-dimensional approach to understanding, measuring, and conquering the three enemies of manufacturing: complexity, variability, and poor leadership. Armed with simple, easy-to-use metrics, interactive factory simulation models, and other original tools, you will

  • Cut cycle times
  • Increase capacity
  • Reduce variability in outs and lead times
  • Decluster starts and maintenance events
  • Root out performance-killing company politics and turf battles
  • Create a culture of continual performance improvement


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