Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

Alin Posteucă

by Productivity Press, New York (USA), Oct. 2018

MCPD Transformation Dr. Posteuca

Manufacturing Cost Policy Deployment (MCPD) Transformation: Uncovering Hidden Reserves of Profitability

Alin Posteucă

by Productivity Press, New York (USA), Feb. 2018


Manufacturing Cost Policy Deployment (MCPD) and Methods Design Concept (MDC): The Path to Competitiveness

Alin Posteucă, Shigeyasu Sakamoto

by Productivity Press, New York (USA), 2017

Editorial Reviews
Reveal your hidden Productivity!

Sometimes you need to do the hard work of understanding the data - data can uncover the secrets of your operations: the good, the bad … and the ugly. And sometimes, you need to work at the detailed level to fully understand what is going on … and uncover why.

The MPCD approach does this - works at the detailed, data level to uncover those secrets. But more than this - it drives forward progress. It uses targets to motivate, to challenge and to provide evidence - of the possible, the realistic, the ‘truth’. Managers can then work at a daily level to identify why these targets are not being met - and to improve operations so that the targets are met, regularly and consistently. MPCD deployment puts those managers firmly in control. Perhaps most importantly, MPCD provides the links between the ``productivity vision`` and longer-term aims -- and the goals and action plans that drive shorter-term improvement. Adopting and using the MPCD system releases hidden reserves of productivity and profitability.

Alin has done a remarkable job of condensing a lot of detailed information into a readable, interesting and challenging book. If you are the type of manager who values evidence-based policy determination and decision-making, then MPCD is the approach for you. If you are not yet convinced, read the results of case examples - this approach works!

John Heap, President of the World Confederation of Productivity Science
This book is a new, original, scientific, methodical and a practical approach toward reducing the production costs in a manufacturing environment. Through his professional education, practical involvement and exposure to the everyday production problems, Mr. Posteuca, PhD, is presenting, both, to the academia and to the production floor people, a new type of scientific analysis and activities optimizations.

The book starts with an excellent description of the manufacturing environment problems and needs and then the new approaching method is introduced and explained in terms that can be easily understood not only by college educated professionals, but also by a large amount of people who are working every day in manufacturing plants and have to resolve so many issues.

At the end, the book is analyzing manufacturing samples from everyday life and is proposing practical solutions the optimize the good ones or remove the bad ones.

After spending a pleasant time reading and professionally enlightening myself, I highly recommend this book to anyone interested in improving the efficiency of his manufacturing process he is in charge!

Florin Larion, Lean-Six Sigma Master Black Belt, Philadelphia, USA
The approach from this book is great. Through this book, Alin Posteucă is helping organizations to uncover the hidden potential of profitability through understanding of manufacturing costs behind losses and waste in product families costs flow and alignment of improvement actions and initiatives to achieve Manufacturing Cost Improvement (MCI) goal. The MCPD system is addressing the top management that needs to meet profitability targets by strategic and operational improvement of manufacturing efficiency, but very important, this transformation is based on all workforce engagement on this path.

In his book, Alin is describing the needs for this strategy (the why?) and the steps for this transformation system implementation for tangible and consistent fulfillment of MCI (the how?). And the case study presented in the 3rd section of the book is an eye-wide opener for the organizations on the road for this strategy deployment implementation, with all the links between product families manufacturing flow, cost of losses and waste understanding, actions or improvement initiatives throughout the manufacturing flow, levels in the organization and the annual MCI goal.

Catalin Neagoe, Lead Black Belt, Cameron, a Schlumberger company
It is a clear, coherent and very well-structured book up to the smallest details that channel your attention and look at the manufacturing companies' operations as a true ``exploded view`` to identify real opportunities for consistent and continuous manufacturing cost improvement (MCI) through the MCPD system.

Most of the times, we design, build and use the equipment without the natural ambition to closely and continually monitor their consumption (time spent in detail, spare parts, utilities, etc.). This ``exploded view`` of the manufacturing process is a way of reverting / resetting every time the logic that we often think is perfect to release hidden reserves of productivity and profitability.

The real practical applications presented in the book are very useful. For example, replacing bottleneck operations is an example of how to use this ``exploded view`` of data and information to trigger tangible action to increase productivity to deliver the ROI target in line with the company's expectations - we have simulated this case study and can confirm its practical applicability.

Really remarkable the effort to simultaneously capture the details and the overall picture of the processes!

Gabriel Hîncu, Plant Maintenance Manager, ZF Group-TRW Airbag Systems
Once I got the chance to review Manufacturing Cost Deployment (MCPD) Transformation: Uncovering Hidden Reserves of Profitability, I was prepared for documented, precise, deeply connected to operational realities work. I was not disappointed: well structured, proving deep knowledge of Lean and financial aspects, this book is not a ``quick fix`` tool, but a real asset if you are looking for multiannual approach, team involvement and company culture turnaround. More: it openly speaks, straight from beginning, about main barriers to consistent/sustainable transformation of manufacturing companies- among which, lack of real managerial commitment is pointed as decisive one.

I would also particularly highlight the three case studies at the end of the book: accurate on defining the issue, providing clear ``pattern`` and road-map on MPCD implementation, result analyze and conclusion. A lecture to consider for each manager passionate on improving his results!

Ovidiu Ambrus, Plant Manager at Litens Automotive Eastern Europe (Litens Automotive Group)
Reading this book it becomes obvious that a newer methodology of implementing the costs and efficiencies required in the 21st century across the world has been just published.

From my personal perspective, this the manual that many educators and trainers are missing from their tool boxes because it makes the connection between the different methodologies used by the organizations plus it brings the Cost Transformation and Profitability back into the discussion of why we need projects and educators to be involved in organizational transformations.

Throughout the book, I read the new methodology with steps that will be implemented rigorously as Need for Continuous Cost Reduction, to Transformation, Implementation and Consistency to achieve Manufacturing Cost Improvement. The two cases are well detailed such that many organizations can follow the plan, while training and education can be consistently developed by those who consider Kaizen and Kaikaku as being at the heart of any process.

Dorina Grossu, Professor eLearning, BITSPEC Lean Six Sigma certification