Cost Management in Plastics Processing: Strategies, Targets, Techniques, and Tools, Fourth Edition, makes readers think about current practices and how to go forward with effective cost management. This is a practical workbook that provides a structured approach to reducing costs in plastics processing for all the major plastics shaping processes (moulding, extrusion, forming) as well as elsewhere in the company (e.g., in factory services and non-manufacturing areas).
Competition in all manufacturing sectors is increasing, and there is continuous pressure to drive costs down and to increase cost management. Good cost management improves profits and margins, improves management control and opens the door to becoming a world-class company. The approach throughout this book looks rigorously at where costs are incurred and proposes projects and targets for cost reduction. This book is designed to provide a well-structured map broken down into simple tasks and achievable goals.
This book offers a structured approach to the techniques of cost management, from how costs are calculated by accountants, to the effective use of machines and labor, to the minimization of waste. It begins by looking at traditional methods of accounting and costing and whether these are helpful or accurate for project management. Practical examples of cost management in plastics processing are included, together with many useful flow charts and diagrams to illustrate the points under discussion.
1. 4.25 Risk assessment – introduction - p. 169 2. 4.26 Risk assessment – quality - p. 171 3. 4.27 Risk assessment – environmental - p. 173 4. 4.28 Risk assessment – health and safety - p. 175 5. 4.29 Risk assessment – where are you now? - p. 177 6. 4.30 Business continuity planning - p. 178 7. Key tips - p. 181 8. Chapter 5: Production - p. 183 9. 5.1 The manufacturing strategy - p. 183 10. 5.2 Production control systems - p. 185 11. 5.3 MRP/MRPII/ERP systems - p. 187 12. 5.4 JIT systems - p. 189 13. 5.5 OPT systems - p. 191 14. 5.6 Production control systems – where are you now? - p. 193 15. 5.7 Process design and development - p. 195 16. 5.8 Product and process validation - p. 197 17. 5.9 Waste and non-value activities - p. 199 18. 5.10 Work cells - p. 201 19. 5.11 Machine size - p. 203 20. 5.12 Tool acceptance and initial machine setting - p. 205 21. 5.13 Machine operation - p. 207 22. 5.14 Machine maintenance - p. 209 23. 5.15 Machine utilisation - p. 211 24. 5.16 Economic batch quantity - p. 213 25. 5.17 Set-up time - p. 215 26. 5.18 Scheduling and batching - p. 217 27. 5.19 Factory layout - p. 219 28. 5.20 Manufacturing systems – where are you now? - p. 221 29. 5.21 Supplier development and integration - p. 222 30. 5.22 Quality management - p. 225 31. 5.23 Quality costs/quality savings? - p. 227 32. 5.24 Performance measurement - p. 229 33. 5.25 Performance measurement – where are you now? - p. 231 34. 5.26 Culture change and training - p. 232 35. 5.27 Mass customisation and additive manufacturing - p. 235 36. Key tips - p. 237 37. Chapter 6: Overheads - p. 239 38. 6.1 Fixed and variable costs - p. 239 39. 6.2 Controllable and non-controllable overheads - p. 241 40. 6.3 Energy – a new critical cost - p. 243 41. 6.4 Energy – the vital questions - p. 245 42. 6.5 Energy – more vital questions - p. 247 43. 6.6 Energy – internal site benchmarking - p. 249 44. 6.7 Energy – performance assessment and forecasting - p. 251 45. 6.8 Energy – external benchmarking by site - p. 253 46. 6.9 Energy – external benchmarking by machine - p. 255 47. 6.10 Energy – integrating energy into the accounts - p. 257 48. 6.11 Energy – measuring energy costs - p. 259 49. 6.12 Energy – the site energy survey - p. 261 50. 6.13 Energy – injection moulding - p. 263 51. 6.14 Energy – all-electric injection moulding machines - p. 265 52. 6.15 Energy – extrusion - p. 267 53. 6.16 Energy – extrusion blow moulding - p. 269 54. 6.17 Energy – motors - p. 271 55. 6.18 Energy – compressed air - p. 273 56. 6.19 Energy – cooling water - p. 275 57. 6.20 Energy – drying - p. 277 58. 6.21 Energy – buildings - p. 279 59. 6.22 Energy – carbon footprinting - p. 281 60. 6.23 Energy: general management – where are you now? - p. 283 61. 6.24 Energy: financial management – where are you now? - p. 284 62. 6.25 Energy: technical management – where are you now? - p. 286 63. 6.26 Energy: awareness and information – where are you now? - p. 288 64. 6.27 Waste – waste minimisation - p. 290 65. 6.28 Waste – the site waste survey - p. 293 66. 6.29 Waste – assessing performance - p. 295 67. 6.30 Waste – tools for waste minimisation - p. 297 68. 6.31 Waste – managing waste minimisation - p. 299 69. 6.32 Waste minimisation – where are you now? - p. 301 70. Key tips - p. 302 71. Chapter 7: Data, information and the smart factory - p. 305 72. Chapter 8: Tools for cost management - p. 327 73. Postscript - p. 352 74. Abbreviations and acronyms - p. 353
Cost Management in Plastics Processing: Strategies, Targets, Techniques, and Tools, Fourth Edition, makes readers think about current practices and how to go forward with effective cost management. This is a practical workbook that provides a structured approach to reducing costs in plastics processing for all the major plastics shaping processes (moulding, extrusion, forming) as well as elsewhere in the company (e.g., in factory services and non-manufacturing areas).
Competition in all manufacturing sectors is increasing, and there is continuous pressure to drive costs down and to increase cost management. Good cost management improves profits and margins, improves management control and opens the door to becoming a world-class company. The approach throughout this book looks rigorously at where costs are incurred and proposes projects and targets for cost reduction. This book is designed to provide a well-structured map broken down into simple tasks and achievable goals.
This book offers a structured approach to the techniques of cost management, from how costs are calculated by accountants, to the effective use of machines and labor, to the minimization of waste. It begins by looking at traditional methods of accounting and costing and whether these are helpful or accurate for project management. Practical examples of cost management in plastics processing are included, together with many useful flow charts and diagrams to illustrate the points under discussion.
1. 4.25 Risk assessment – introduction - p. 169 2. 4.26 Risk assessment – quality - p. 171 3. 4.27 Risk assessment – environmental - p. 173 4. 4.28 Risk assessment – health and safety - p. 175 5. 4.29 Risk assessment – where are you now? - p. 177 6. 4.30 Business continuity planning - p. 178 7. Key tips - p. 181 8. Chapter 5: Production - p. 183 9. 5.1 The manufacturing strategy - p. 183 10. 5.2 Production control systems - p. 185 11. 5.3 MRP/MRPII/ERP systems - p. 187 12. 5.4 JIT systems - p. 189 13. 5.5 OPT systems - p. 191 14. 5.6 Production control systems – where are you now? - p. 193 15. 5.7 Process design and development - p. 195 16. 5.8 Product and process validation - p. 197 17. 5.9 Waste and non-value activities - p. 199 18. 5.10 Work cells - p. 201 19. 5.11 Machine size - p. 203 20. 5.12 Tool acceptance and initial machine setting - p. 205 21. 5.13 Machine operation - p. 207 22. 5.14 Machine maintenance - p. 209 23. 5.15 Machine utilisation - p. 211 24. 5.16 Economic batch quantity - p. 213 25. 5.17 Set-up time - p. 215 26. 5.18 Scheduling and batching - p. 217 27. 5.19 Factory layout - p. 219 28. 5.20 Manufacturing systems – where are you now? - p. 221 29. 5.21 Supplier development and integration - p. 222 30. 5.22 Quality management - p. 225 31. 5.23 Quality costs/quality savings? - p. 227 32. 5.24 Performance measurement - p. 229 33. 5.25 Performance measurement – where are you now? - p. 231 34. 5.26 Culture change and training - p. 232 35. 5.27 Mass customisation and additive manufacturing - p. 235 36. Key tips - p. 237 37. Chapter 6: Overheads - p. 239 38. 6.1 Fixed and variable costs - p. 239 39. 6.2 Controllable and non-controllable overheads - p. 241 40. 6.3 Energy – a new critical cost - p. 243 41. 6.4 Energy – the vital questions - p. 245 42. 6.5 Energy – more vital questions - p. 247 43. 6.6 Energy – internal site benchmarking - p. 249 44. 6.7 Energy – performance assessment and forecasting - p. 251 45. 6.8 Energy – external benchmarking by site - p. 253 46. 6.9 Energy – external benchmarking by machine - p. 255 47. 6.10 Energy – integrating energy into the accounts - p. 257 48. 6.11 Energy – measuring energy costs - p. 259 49. 6.12 Energy – the site energy survey - p. 261 50. 6.13 Energy – injection moulding - p. 263 51. 6.14 Energy – all-electric injection moulding machines - p. 265 52. 6.15 Energy – extrusion - p. 267 53. 6.16 Energy – extrusion blow moulding - p. 269 54. 6.17 Energy – motors - p. 271 55. 6.18 Energy – compressed air - p. 273 56. 6.19 Energy – cooling water - p. 275 57. 6.20 Energy – drying - p. 277 58. 6.21 Energy – buildings - p. 279 59. 6.22 Energy – carbon footprinting - p. 281 60. 6.23 Energy: general management – where are you now? - p. 283 61. 6.24 Energy: financial management – where are you now? - p. 284 62. 6.25 Energy: technical management – where are you now? - p. 286 63. 6.26 Energy: awareness and information – where are you now? - p. 288 64. 6.27 Waste – waste minimisation - p. 290 65. 6.28 Waste – the site waste survey - p. 293 66. 6.29 Waste – assessing performance - p. 295 67. 6.30 Waste – tools for waste minimisation - p. 297 68. 6.31 Waste – managing waste minimisation - p. 299 69. 6.32 Waste minimisation – where are you now? - p. 301 70. Key tips - p. 302 71. Chapter 7: Data, information and the smart factory - p. 305 72. Chapter 8: Tools for cost management - p. 327 73. Postscript - p. 352 74. Abbreviations and acronyms - p. 353
