Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems

743 Pages·2020·155.012 MB·English

by  Shahrukh A. Irani

Job Shop Lean
Taylor & Francis
Taylor & Francis Group
http://taylorandfrancis.com
Job Shop Lean
An Industrial Engineering Approach
to Implementing Lean in High-Mix
Low-V olume Production Systems
Shahrukh A. Irani
First published 2020
by Routledge
52 Vanderbilt Avenue, New York, NY 10017
and by Routledge
2 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
Routledge is an imprint of the Taylor & Francis Group, an informa business
© 2020 Taylor & Francis
The right of Shahrukh Irani to be identified as author of this work has been asserted by him in accordance with
sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by any electronic,
mechanical, or other means, now known or hereafter invented, including photocopying and recording, or in any
information storage or retrieval system, without permission in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for
identification and explanation without intent to infringe.
ISBN: 978-0-367-47225-2 (hbk)
ISBN: 978-1-4987-4069-2 (pbk)
ISBN: 978-1-003-03418-6 (ebk)
Typeset in Garamond
by codeMantra
This book is dedicated to my late parents, Ardeshir Irani
and Freni Irani, who embodied moral values, kindness,
generosity, decency, humility, and love for the family.
Taylor & Francis
Taylor & Francis Group
http://taylorandfrancis.com
Contents
Foreword ..................................................................................................xix
Testimonial ..............................................................................................xxi
Acknowledgments ................................................................................xxiii
Author .....................................................................................................xxv
1 About This Book ..........................................................................1
The Genesis of Job Shop Lean ...................................................................1
The Toyota Production System (and Lean) Gave GT/CM a New
Lease of Life ................................................................................................2
What This Book Teaches ............................................................................8
Reading Plan for This Book......................................................................10
Appendices for Select Chapters in This Book .........................................15
Supplementary Reading for Select Chapters in This Book ......................17
What’s Next? ..............................................................................................19
Software to Implement Job Shop Lean ....................................................19
What This Book Does Not Teach ..............................................................21
Management-Oriented Books on Lean ...................................................21
Appendices ................................................................................................22
References .................................................................................................22
2 Introduction to Job Shop Lean ..................................................25
Lean Is Necessary for Every Manufacturer but … ...................................25
… Lean Is Also Insufficient for Many Manufacturers ..............................25
How a Job Shop Differs from an Assembly Line .....................................27
An Assembly Line Is Inflexible Compared to a Job Shop .......................28
High-Mix Low-Volume Manufacturers with Job Shop-Like
Manufacturing Facilities ............................................................................28
Primary Focus of Job Shop Lean..............................................................29
A Standard Process for Implementing Lean .............................................35
vii
viii ◾ Contents
Adapting the Lean Thinking Process to Implement Job Shop Lean .......37
A Comprehensive Approach for Implementing Job Shop Lean ..............39
Illustration of the Comprehensive Approach for Implementing Job
Shop Lean ..................................................................................................41
Appendices ................................................................................................46
References .................................................................................................47
3 Is Job Shop Lean Right for You? ................................................49
4 Design For Flow (DFF): The Essential Foundation for Job
Shop Lean ..................................................................................57
A Tribute to Manufacturing Pioneers of the Past .....................................57
Flow: The Essential Foundation for Job Shop Lean .................................62
Flow Delays and the Seven Types of Waste ............................................65
Quick-and-Dirty Estimation of the Monetary Value of Any Waste
and/or Flow Delay ....................................................................................69
Design for Flow: Principles for Factory Layout Design to Achieve Flow ....72
Role of Product Design and Manufacturing Engineering ........................77
How to Assess If a Factory Layout Is Designed for Flow ........................80
An Approach for Designing a Factory Layout to Achieve Flow ..............80
How to Achieve Flow If the Factory Layout Cannot Be Changed ..........80
Conclusion .................................................................................................87
Appendices ................................................................................................87
References .................................................................................................87
5 Overview of Production Flow Analysis (PFA)............................89
Production Flow Analysis (PFA) ...............................................................90
Stages for Implementing Production Flow Analysis ................................90
Software to Implement PFA ......................................................................98
Data Needed to Implement PFA ...............................................................98
Conclusion ...............................................................................................100
References ...............................................................................................100
6 Overview of Production Flow Analysis and Simplification
Toolkit (PFAST) .......................................................................101
7 Functional, Cellular, and Hybrid Cellular Layouts for Any
Job Shop. ..................................................................................107
Functional Layout vs. Cellular Layout ....................................................107
A Cellular Layout Is Not a Panacea! .......................................................108
Design of Flexible and Lean (FLean) Layouts for Job Shops ................109
Contents ◾ ix
Hybrid Cellular Layouts ..........................................................................109
Conclusion ...............................................................................................115
8 Designing Functional, Cellular, and Hybrid Cellular Layouts
for Any Job Shop Using PFAST ................................................117
Background .............................................................................................117
Is the Functional Layout Really the Best Layout for a Job Shop? ..........118
Fundamental Challenge of Designing a “Best Fit” Layout for Any
Job Shop ..................................................................................................118
Designing Alternative Layouts for Any Job Shop Using PFAST ............119
Input Data ...............................................................................................120
Product-Quantity Analysis (PQ Analysis) ...............................................121
How to Do PQ Analysis ........................................................................122
How to Use PQ Analysis ........................................................................123
Product-Quantity-Revenue Analysis (PQ$ Analysis) ..............................123
How to Do PQ$ Analysis ......................................................................124
How to Use PQ$ Analysis ......................................................................125
From-To Chart .........................................................................................127
How to Create a From-To Chart ............................................................127
How to Use the From-To Chart ..............................................................128
Product-Routing Analysis Type I (PR-I Analysis) and
Product-Routing Analysis Type II (PR-II Analysis) .................................130
How to Do PR-I Analysis ........................................................................130
How to Do PR-II Analysis.......................................................................132
How to Use PR-I Analysis and PR-II Analysis ........................................135
Product-Routing Analysis Type IV (PR-IV Analysis) ..............................136
How to Do PR-IV Analysis ....................................................................139
How to Use PR-IV Analysis ....................................................................140
Product-Routing Analysis Type III (PR-III Analysis) ..............................142
How to Do PR-III Analysis ....................................................................143
How to Use PR-III Analysis ....................................................................144
Conclusion ...............................................................................................146
Supplementary Reading ..........................................................................146
References ...............................................................................................147
9 How Data Mining Guides Various Production Flow
Simplification Strategies ..........................................................149
Variety of Flow Simplification Strategies Enabled by PFAST .................150
Management Actions Based on LAT-Aided Recommendations ............151