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Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems
Shahrukh A. Irani
CRC Press, 04-May-2020 - Business & Economics - 744 pages
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
Made-to-Order Lean: Excelling in a High-Mix, Low-Volume Environment
Greg Lane
CRC Press, 09-Mar-2020 - Business & Economics - 224 pages
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: glane@lowvolumelean.com
https://books.google.co.in/books?id=mYvVDwAAQBAJ
UNIVERSITÀ DI PISA - Dottorato di Ricerca in Ingegneria Industriale.
Development and implementation of Lean Manufacturing tools and methods for the manufacturing efficiency in Engineer-to-Order production environments
MARRAZZINI, LEONARDO
https://etd.adm.unipi.it/t/etd-08182020-100440/
"Overall Task Effectiveness: a new Lean performance indicator in engineer-to-order environment,"
Marcello Braglia, Roberto Gabbrielli and Leonardo Marrazzini,
Dipartimento di Ingegneria Civile e Industriale,
Università di Pisa, Pisa, Italy.
International Journal of Productivity and Performance Management, Vol. 68 No. 2, 2019, pp. 407-422
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