Job Shop Lean
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Author | : Shahrukh A. Irani |
Publisher | : CRC Press |
Total Pages | : 725 |
Release | : 2020-05-04 |
Genre | : Business & Economics |
ISBN | : 1000055612 |
In the 1950’s, the design and implementation of the Toyota Production System (TPS) within Toyota had begun. In the 1960’s, Group Technology (GT) and Cellular Manufacturing (CM) were used by Serck Audco Valves, a high-mix low-volume (HMLV) manufacturer in the United Kingdom, to guide enterprise-wide transformation. In 1996, the publication of the book Lean Thinking introduced the entire world to Lean. Job Shop Lean integrates Lean with GT and CM by using the five Principles of Lean to guide its implementation: (1) identify value, (2) map the value stream, (3) create flow, (4) establish pull, and (5) seek perfection. Unfortunately, the tools typically used to implement the Principles of Lean are incapable of solving the three Industrial Engineering problems that HMLV manufacturers face when implementing Lean: (1) finding the product families in a product mix with hundreds of different products, (2) designing a flexible factory layout that "fits" hundreds of different product routings, and (3) scheduling a multi-product multi-machine production system subject to finite capacity constraints. Based on the Author’s 20+ years of learning, teaching, researching, and implementing Job Shop Lean since 1999, this book Describes the concepts, tools, software, implementation methodology, and barriers to successful implementation of Lean in HMLV production systems Utilizes Production Flow Analysis instead of Value Stream Mapping to eliminate waste in different levels of any HMLV manufacturing enterprise Solves the three Industrial Engineering problems that were mentioned earlier using software like PFAST (Production Flow Analysis and Simplification Toolkit), Sgetti and Schedlyzer Explains how the one-at-a-time implementation of manufacturing cells constitutes a long-term strategy for Continuous Improvement Explains how product families and manufacturing cells are the basis for implementing flexible automation, machine monitoring, virtual cells, Manufacturing Execution Systems, and other elements of Industry 4.0 Teaches a new method, Value Network Mapping, to visualize large multi-product multi-machine production systems whose Value Streams share many processes Includes real success stories of Job Shop Lean implementation in a variety of production systems such as a forge shop, a machine shop, a fabrication facility and a shipping department Encourages any HMLV manufacturer planning to implement Job Shop Lean to leverage the co-curricular and extracurricular programs of an Industrial Engineering department
Author | : Vincent Bozzone |
Publisher | : AMACOM/American Management Association |
Total Pages | : 268 |
Release | : 2001 |
Genre | : Business & Economics |
ISBN | : 9780814426609 |
Lean manufacturing is the single most effective way to increase sales, cut costs, improve margins, and secure the future of a business. The problem is that the principles and philosophies of lean manufacturing are geared strictly to mass production operations and can be ineffective, even detrimental, for smaller job shops and make-to-order businesses. Now, Speed to Market delivers a proven approach for smaller suppliers who want to successfully cut their lead time and trigger profitable growth. Completely updated and expanded, the book explains how to: * Apply the principles of pull, flow, and the elimination of waste to every area of the company, at every stage from quotes to cash* Implement a continuous improvement process while sidestepping the typical implementation pitfalls* Ease scheduling problems* Improve performance and profitability using the book's practical concepts, process analysis tools, and perspective-enhancing techniques and much more
Author | : Gary Conner |
Publisher | : Society of Manufacturing Engineers |
Total Pages | : 361 |
Release | : 2009 |
Genre | : Business & Economics |
ISBN | : 0872638588 |
A how-to guide to shortening delivery times, eliminating waste, improving quality, and reducing costs. It describes not only what to do, but includes many tools useful to the reader describing how to do it. It explores tools including kaizen, value stream mapping, takt time, determining optimum lot sizes, setup reduction and problem solving.
Author | : Greg Lane |
Publisher | : CRC Press |
Total Pages | : 281 |
Release | : 2020-03-09 |
Genre | : Business & Economics |
ISBN | : 142008688X |
Toyota Production System methods have rendered remarkable results in high-volume manufacturing plants, but they have not been fully understood and correctly applied in high-mix, low-volume environments. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low-volume environment. This volume is specifically geared for manufacturers that have hundreds to thousands of active part numbers with few or no ongoing forecasted volumes, and for job shops that build only to order. The primary focus is eliminating non-value-added activities and instituting improvements on the most repetitive jobs, a strategy that gives you more time to produce your low-volume work or one-offs. About the author: Greg Lane is a faculty member of the Lean Enterprise Institute and an advisor to the Instituto de Lean Management in Spain. During his time with Toyota, he was one of a handful of candidates selected for a one-year training program conducted by the company’s masters. He became certified as a Toyota Production System (TPS) Key Person and continued his work with Toyota, training others in TPS. He has been highly active in working on implementing lean around the world, supporting large and small companies alike. In 1998, he began to focus his lean endeavors on meeting the specific needs of high-mix, low-volume enterprises. During his time as an independent consultant, Greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high-mix, low-volume parts. Greg used TPS to grow the business and nearly double its sales. Greg and his associates have experience not only at adapting the methods contained in this book, but also in applying other tools that are too numerous to detail here. They can be reached for further support with your lean transformation via email: [email protected]
Author | : Shahrukh Irani |
Publisher | : Productivity Press |
Total Pages | : 352 |
Release | : 2016-05-15 |
Genre | : Business & Economics |
ISBN | : 9781498740692 |
The book integrates tehniques from the Toyota Production System (TPS) that apply to high-mix low-volume with the science of Group Technology and Cellular Manufacturing (GT/CM) to replace those parts of theTPS that pertain solely to high-volume, repeatable processes. GT/CM is the technical solution to Lean for high-mix low-volume. Toyota provides the tools to sustain GT/CM, especially the workforce culture and Lean leadership aspects
Author | : Roger Kremer |
Publisher | : MCS Media, Inc. |
Total Pages | : 104 |
Release | : 2005 |
Genre | : Costs, Industrial |
ISBN | : 9780972572859 |
Author | : Greg Lane |
Publisher | : Productivity Press |
Total Pages | : 0 |
Release | : 2009-12-17 |
Genre | : Business & Economics |
ISBN | : 9781439815168 |
This is the true story of how, armed with only Lean improvement methodologies, a specially trained Toyota Lean expert purchased a business he knew nothing about, applied Lean techniques, and succeeded in doubling sales and increasing profitability, before he finally sold the thriving business. With humility and humor, the author recounts his successes and failures, introduces his key employees and their struggles with change, and provides motivation and simple ideas for all readers looking to improve their businesses. He captures key points highlighted in text boxes and includes illustrative photos and examples of Lean tools at work. This story dispels the fallacy that Lean management does not achieve excellent results in high variation companies and job shops. Toyota’s OSKKK methodology is introduced to understand processes and guide a Lean transformation on the shop floor and in the office.
Author | : Charles Protzman |
Publisher | : CRC Press |
Total Pages | : 1602 |
Release | : 2018-09-03 |
Genre | : Business & Economics |
ISBN | : 1315362872 |
While there are numerous Lean Certification programs, most companies have their own certification paths whereby they bestow expert status upon employees after they have participated in or led a certain number of kaizen events. Arguing that the number of kaizen events should not determine a person's expert status, The Lean Practitioner's Field Book: Proven, Practical, Profitable and Powerful Techniques for Making Lean Really Work outlines a true learning path for anyone seeking to understand essential Lean principles. The book includes a plethora of examples drawn from the personal experiences of its many well-respected and award-winning contributors. These experts break down Lean concepts to their simplest terms to make everything as clear as possible for Lean practitioners. A refresher for some at times, the text provides thought-provoking questions with examples that will stimulate learning opportunities. Introducing the Lean Practitioner concept, the book details the five distinct Lean Practitioner levels and includes quizzes and criteria for each level. It highlights the differences between the kaizen event approach and the Lean system level approach as well as the difference between station balancing and baton zone. This book takes readers on a journey that begins with an overview of Lean principles and culminates with readers developing professionally through the practice of self-reliance. Providing you with the tools to implement Lean tools in your organization, the book includes discussions and examples that demonstrate how to transition from traditional accounting methods to a Lean accounting system. The book outlines an integrated, structured approach identified by the acronym BASICS (baseline, analyze, suggest solutions, implement, check, and sustain), which is combined with a proven business strategy to help ensure a successful and sustainable transformation of your organization.
Author | : Matthew Zayko |
Publisher | : CRC Press |
Total Pages | : 253 |
Release | : 2021-10-28 |
Genre | : Business & Economics |
ISBN | : 1000462021 |
Lean Process Creation teaches the specific frames—the 6CON model—to look through to properly design any new process while optimizing the value-creating resources. The framing is applicable to create any process that involves people, technology, or equipment—whether the application is in manufacturing, healthcare, services, retail, or other industries. If you have a process, this approach will help. The result is 30% to 50% improvement in first-time quality, customer lead time, capital efficiency, labor productivity, and floorspace that could add up to millions of dollars saved per year. More important, it will increase both employee and customer satisfaction. The book details a case study from a manufacturing standpoint, starting with a tangible example to reinforce the 6CON model. This is the first book written from this viewpoint—connecting a realistic transformation with the detailed technical challenges, as well as the engagement of the stakeholders, each with their own bias. Key points and must-do actions are sprinkled throughout the case study to reinforce learning from the specific to the general. In this study, an empowered working team is charged with developing a new production line for a critical new product. As the story unfolds, they create an improved process that saves $5.6 million (10x payback on upfront resource investment) over the short life cycle of the product, as well as other measurable benefits in quality, ergonomics, and delivery. To an even greater benefit, they establish a new way of working that can be applied to all future process creation activities. Some organizations have tried their version of Lean process design following a formula or cookie-cutter approach. But true Lean process design goes well beyond forcing concepts and slogans into every situation. It is purposeful, scientific, and adaptable because every situation starts with a unique current state. In addition, Lean process design must include both the technical and social aspects, as they are essential to sustaining and improving any system. Observing the recurring problem of reworking processes that were newly launched brought the authors to the conclusion that a practical book focused on introducing the critical frames of Lean process creation was needed. This book enables readers to consider the details within each frame that must be addressed to create a Lean process. No slogans, no absolutes. Real thinking is required. This type of thinking is best learned from an example, so the authors provide this case study to demonstrate the thinking that should be applied to any process. High volume or low, simple or complex mix, manufacturing or service/transactional—the framing and thinking works. Along with the thinking, readers are enabled to derive their own future states. This is demonstrated in the story that surrounds the case study.
Author | : Jim Lancaster |
Publisher | : Lean Enterprise Institute Inc. |
Total Pages | : 184 |
Release | : 2017-07-03 |
Genre | : Business & Economics |
ISBN | : 1934109541 |