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TPS/Lean Tools to Use for HMLV Manufacturing

Who Are We?

Dr. Shahrukh A. Irani is the President of Lean and Flexible, llc, a consulting company that he started in 2014 to deliver consulting and training services in Lean for high-mix low-volume manufacturing (aka JobshopLean). Previously, from 2012-2014, he gained invaluable industry experience as the Director of IE Research at Hoerbiger Corporation of America, Inc., Houston, TX. In that position, he undertook projects to demonstrate the viability of JobshopLean in their high-mix low-volume (HMLV) manufacturing facilities. Prior to his industry job, from 1996-2012, he was an Associate Professor in the Department of Integrated Systems Engineering (ISE) at The Ohio State University (OSU). His research at OSU produced JobshopLean, a comprehensive methodology to adapt Lean for high-mix, low-volume (HMLV) small and medium enterprises (SME). Also, his team developed the PFAST (Production Flow Analysis and Simplification Toolkit) software that facilitates the implementation of JobshopLean.During his sixteen years at OSU, he received the Outstanding Faculty Award for excellence in teaching from the ISE department’s graduating classes of 2002, 2003, 2004, 2005, 2006 and 2009 and the 2002 Charles E. MacQuigg Outstanding Teaching Award from the College of Engineering.He served as the Director of the Facilities Planning and Design (FAPAD) division of the Institute of Industrial Engineers for 1999-2001 and 2001-2003. He is the Editor of the Handbook of Cellular Manufacturing Systems (1999, John Wiley). In 1996, Dr. Irani was voted Young Engineer of the Yearby the Minnesota Federation of Engineering Societies and the Minneapolis Chapter of the Institute of Industrial Engineers.

Testimonials About Our Program

  • Valley Machine is in the process of designing and building a new purpose-built facility for our precision manufacturing requirements and we brought in Dr. Irani early in the process based on a recommendation from a trusted industry contact. Dr. Irani arrived at our facility and quickly came up to speed on our current layout and helped guide us through mapping our product flow as well as multiple iterations for improved flow and lean considerations. Through these exercises, in just over a day’s time we were also able to explore more efficient use of human resources which has helped us to shape staffing philosophies along with product flow and the resulting improved facility layout.

    Andy Spiering
    Valley Machine
  • Thank you for your assistance with the planning and layout of our new manufacturing facility. It was exciting for us to locate someone who specializes in understanding and supporting machining job shops like us, or as you put it, High Mix Low Volume (HMLV) manufacturing operations.

    Robert Savitzky
    R.S. PRECISION INDUSTRIES, INC.
  • The 1st team which was lead by your student Mr. John Wheeler we employed cost Alpha 1 $ 20,000.00 but yielded a cost savings in the targeted areas of $ 8,000.00 per employee. At that time there were only 8 employees in that working cell so at the time the 1st year’s savings equated to $ 64,000.00.

    Jim Dyer
    Alpha 1
  • You and your team are on the cusp of success through the implementation of Job Shop Lean Concepts and the exploitation of the Production Flow Analysis Simplification Toolkit. Since 2001 you have made great strides in not only developing these concepts deeply but also broadly.

    Jon Tirpak
    Forging Industry Association – Department of Defense Manufacturing Consortium

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