Principles of Lean for High-Mix Low-Volume Manufacturing
INTRODUCTION TO THE CLASS
The core of this class is Lean. Lean is based on the Toyota Production System (TPS). This highly sought after management model has been adopted successfully by many industries. Lean organizes manufacturing and logistics to design out overburden and inconsistency while reducing waste. Waste can be in several forms such as overproduction, writing, transportation, over-processing, inventory, defective products, and poorly-utilized employees.
Originally, the TPS was designed for low-mix high-volume (LMHV) product assembly. However, in this class we will show you how to modify and adapt it to your HMLV (high-mix low-volume) manufacturing process. Examples of high-mix low-volume (HMLV) manufacturers are:
any forge shop
any machine shop
any Make-To-Order product fabricator
any repair facility
This class will teach JobshopLean, a modified approach to implement the same Principles of Lean (Source: www.lean.org/WhatsLean/Principles.cfm). JobshopLean utilizes Industrial Engineering practices and methods inspired by the simple, intuitive and proven methods of the Toyota Production System. However, instead of relying on the cumbersome manual methods and tools of Lean, JobshopLean uses computer-aided solution approaches to overcome the challenges of implementing Lean in high-mix low-volume facilities. JobshopLean focuses on the following strategies:
reduction of the three wastes (Transportation, WIP and Waiting) that destroy Cash Flow Velocity
product mix segmentation into part families
shop floor layout reorganization into manufacturing cells
team-based employee engagement in each cell
management involvement in the operations of the cells
Not all HMLV manufacturers will be served well by a single, general class that teaches a cookie-cutter approach to implementing JobshopLean in all HMLV manufacturing facilities. If you would like to have a specific course crafted for you and your organization, please click here for details and email firstname.lastname@example.org.
An attendee should (a) be working for a high-mix low-volume manufacturer, (b) be reasonably conversant with Lean (as based on the Toyota Production System) and (c) have prior experience in implementing Lean. Examples of high-mix low-volume manufacturers would be those that have SIC (Standard Industrial Classification) codes such as 20xx, 23xx, 24xx, 25xx, 31xx, 34xx, 35xx, 36xx, 37xx, 38xx and 39xx. In addition, this class has valuable takeaways for industry professionals with the following job titles:
VP – Operations
Director – Operations
Lean Six Sigma Practitioner
Two or more: $795 each
If you have questions about how this class will apply to your manufacturing environment, please send an email to the Instructor at ShahrukhIrani1023@yahoo.com or call him at 832-475-4447. The instructor can also give you an honest assessment whether the class will benefit your company if you would complete a one-page questionnaire and return it to him at the above address. Alternatively, he could recommend some of his articles on LinkedIn that will provide more background information on JobshopLean.
RESULTS REPORTED BY CLIENTS WHO IMPLEMENTED JOBSHOPLEAN
In the news: Read Lean Manufacturing Begins With Layout, Commitment in the July 2017 issue of Modern Machine Shop Online. The article features work that Dr. Irani did with the team at Wear Technology Inc. to implement JobshopLean in their CNC machine shop.
Weber Metals (Los Angeles, CA) reported a one-time work-in-progress (WIP) inventory avoidance of $3,000,000 after implementing the proposed shop re-layout and scheduling strategy
TECT (Cleveland, OH) reduced floor space requirements with their new layout which reduced their annual facility leasing costs by $350,000
TECT (Cleveland, OH) estimated that their new layout reduced travel time for forgings produced for a key customer by ≈ 85%
Ulven Forging (Hubbard, OR) implemented a new layout and invested in new equipment that resulted in an annual savings of $137,000
Ulven Forging (Hubbard, OR) reduced the average time it took their front office to respond to an RFQ from 10.2 days to 2.4 days
SIFCO Forging Industries (Cleveland, OH) implemented a work cell in their Non-Destructive Testing department that increased Equipment Uptime by 20% and increased Labor Productivity by 10%
Bula Forge & Machine Inc. (Cleveland, OH) reorganized their Shipping Department which eliminated excess work-in-process (WIP) valued at ≈ $130,000
G&G Mfg. Co. (Cincinnnati, OH) implemented a flexible flow cell that reduced Manufacturing Lead Time for a representative part from 12 working days to 5 working days
Alpha 1 Induction Service Center (Columbus, OH) implemented a work cell that yielded a first year’s cost savings of $64,000
Hoerbiger Corporation of America (Houston, TX) estimated that implementation of a machining cell would (1) reduce order fulfillment time from 16 days to 5 days and (2) reduce annual material handling labor by 51 hours
Hoerbiger Corporation of America (Houston, TX) implemented a new layout for their Shipping Department with ≈ 50% less floor space requirements
Hirschvogel Inc. (Columbus, OH) reduced setup time on one of their cold forging presses fro m125 minutes to 94 minutes which enabled an estimated increase in annual production valued at $300,000
CLASS STRUCTURE AND MATERIALS
Each attendee is responsible for bringing their own materials, such as pens, paper and computers. The Instructor will provide the study notes for the class and all materials relevant to each of the different exercises, simulations, etc.
How JobshopLean Adapts and Extends Lean for High-Mix Low-Volume (HMLV) Manufacturing
Flow: The Essential Foundation for Implementing JobshopLean in any Factory
Fundamentals of Waste Identification and Elimination
Manufacturing Cells: How to Design, Operate and Manage Product-focused Teams
SIMULATION - Design and Operation of a Stamping Cell
CASE STUDY - Lessons Learned from Implementing Lean in a Compressor Parts Machining Cell
OPEN FORUM - Is JobshopLean Right For You?
SIMULATION - JobshopLean Practices for High-Mix Low-Volume Custom Products Manufacturing
Sequencing Jobs Through a Flowline Cell
Scheduling a Manufacturing Cell with Finite Capacity Constraints
How Do You Get Started with JobshopLean At Your Place of Work?
If you would like to receive the detailed Agenda for the class, please send an email to the Instructor at ShahrukhIrani1023@yahoo.com or call him at 832-475-4447.
CLASS LEARNING OUTCOMES
Attend a class that teaches valuable concepts and methods for high-mix low-volume manufacturing.
Walk away with a clear vision that JobshopLean blends the best operational practices learned from Group Technology, Cellular Manufacturing, Industrial Engineering, Toyota Production System, etc.
Learn how to use Production Flow Analysis (instead of the manual method of Value Stream Mapping) for implementing Lean in any high-mix low-volume manufacturing facility
Refresh your skills at identifying waste on the shop floor using a Spaghetti Diagram, Value Stream Map and Process Analysis
Study the inner workings of an actual manufacturing cell that uses Lean practices such as Quality-At-Source, Total Productive Maintenance, Poka-Yoke, 5S, Teamwork, Cross-Functional Training Boards, Ergonomics, etc.
Participate in an interactive simulation that tests your academic knowledge and work experience on how best to transform the layout of a machine shop to become Lean and Flexible (FLean)
Participate in an interactive simulation that teaches operational strategies for a manufacturing cell
Participate in two discussions with all attendees (1) Is JobshopLean Right For You? and (2) Where Do You Go From Here?
Learn to collaborate extensively with one or more top-ranked Industrial Engineering programs because every HMLV manufacturer must develop a production system that is best suited to their operations!