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JobshopLean: Adapting Lean for Small and Medium High-Mix Low-Volume Manufacturers
Integrating the Toyota Production System with Group Technology and Cellular Manufacturing


Dr. Shahrukh Irani
Lean & Flexible, llc
4102 Pensacola Oaks Lane
Sugar Land, TX77479
Phone: 832-475-4447
Email: ShahrukhIrani1023@yahoo.com
Website: www.LeanandFlexible.com

Click Titles to Open Chapter (Must buy the book to view chapters)

Chapter Title Supplementary Reading
1 How Lean Transformed the Career of an Industrial Engineering (IE) Faculty

Appendix 1 “Textbook IE” versus “Toyota IE”

Appendix 2 Literature that Describes Projects where PFAST was Successfully Used

Appendix 3 Results Delivered to Small and Medium Enterprises (SME) by OSU Interns

Appendix 4 Components of a Comprehensive Program for Service to Industry

Appendix 5 Suggestions for IE Faculty Committed to Undergraduate Teaching

2 Introduction to JobshopLean
Appendix 1 A Chronological Bibliography on Group Technology
Appendix 2 Literature on JobshopLean
Appendix 3 E-book and Business Guide on JobshopLean
3 Is JobshopLean Right For You?
4 The Essential Foundation for JobshopLean
Appendix 1 Guidelines for Designing a Good Factory Layout
Appendix 2 A Detailed Checklist to Evaluate any Factory Layout
Appendix 3 A Lean Checklist to Evaluate any Factory Layout
Appendix 4 How to Achieve Flow without Factory Layout Changes?
5 Overview of Production Flow Analysis (PFA)
6 Overview of Production Flow Analysis and Simplification Toolkit (PFAST)
7 Functional, Cellular and Hybrid Cellular Layouts for any Job Shop
8 Designing Functional, Cellular and Hybrid Cellular Layouts for any Job Shop using PFAST
  1. Quick-Read Guide on Product-Process Matrix Analysis
  2. Quick-Read Guide on Product-Routing Cluster Analysis
  3. Design of a Cellular Layout for an Entire Facility
  4. Production Flow Analysis: A Tool for Designing a Lean Hospital
9 How Data Mining Guides Various Production Flow Simplification Strategies (Workbook) Lean Advisory Tools for Jobshops
10 Improving Flow at any Level in a Factory
11 Industry Applications of Production Flow Analysis by Industrial Engineering (IE) Students

Appendix 1 A Comparison of “Textbook IE” and “Toyota IE”

Appendix 2 Syllabus for Undergraduate Course on Process Analysis and Improvement

Appendix 3 Syllabus for Undergraduate Course on Facilities Design

Appendix 4 Syllabus for Undergraduate Course on Production Control and Scheduling

Appendix 5 Syllabus for Graduate Course on JobshopLean

(See Table 1 of the Chapter) Reports for Student Projects:

12 Production Flow Analysis using a Flow Diagram
  1. Presentations on Using Spaghetti Diagrams for Material Flow Assessment
  2. Exercise on Waste Identification: Entire Factory
  3. Exercise on Waste Identification: Single Cell
  4. Fundamentals of Process Analysis and Improvement
  5. An IE Instructor’s Guide to Teach Process Analysis  and Improvement using the Toast Kaizen Video
  6. Case Study on Process Improvement
  7. Case Study: Implementing the Quick-Start Approach for JobshopLean at Bula Forge & Machine Inc.
  8. Case Study: Implementing the Quick-Start Approach for JobshopLean at Ulven Forging Inc.
Appendix 1 Production Flow Analysis using a Flow Diagram: Single Routing
Appendix 2 Production Flow Analysis using a Flow Diagram: Many Routings
13 Product Mix Segmentation
14 Determining the Correct Layout Shape for a High-Mix Machining Cell
15 Design of a Flexible and Lean (FLean) Machining Cell Design of a Flexible and Lean (FLean) Manual Packings Cell
Appendix 1 Support Systems for a Flexible and Lean (FLean) Manufacturing Cell
Appendix 2 Checklist for Implementing a Manufacturing Cell
16 How Cell Formation Drives the Implementation of JobshopLean

  • Interacting Problems in Cell Formation
  • STRATEGY MAP #1: Strategies to reduce or eliminate inter-cell flows of parts that utilize available capacity on shared machines distributed in several cells that ARE NOT Monuments
  • STRATEGY MAP #2: Strategies to reduce, better yet eliminate inter-cell flows of parts that utilize available capacity on shared machines that ARE Monuments
This chapter is based on the LAT for Feasibility Analysis for Cellular Manufacturing.
17 (Prasad Velaga) Scientific Management of High-Variety and Complex Production in Job Shops (Aparecido Martins, Aparecido@aps3.com.br) Implementation of Finite Capacity Scheduling at Hercules-Motors (A condensed version of this case study is available at http://preactor.com/Case-Study/Case-Studies/Hercules-Motors#.VoMCL_krK1s)
18 (Prasad Velaga) Pull vs. Controlled Push in High-Variety Discrete Manufacturing
19 Introduction to Operations Scheduling for High-Mix Low-Volume Manufacturers
  1. Scheduling an M-machine Flowshop to Minimize Makespan
  2. An IE Student’s Study Guide for Bottleneck Scheduling using Theory Of Constraints
  3. Introduction to Flowshop Scheduling
  4. Case Study on Flowshop Scheduling
  5. Scheduling a 5-machine Flowshop
  6. [Solution Key] Releasing Orders to a Cell with Capacity Constraints
Appendix 1 VelFlow: A Simulator for Evaluating High-Mix Low-Volume Production Lines
Appendix 2 Releasing Orders to a Cell with Capacity Constraints
20 Finite Capacity Scheduling of a Flexible and Lean (FLean) Cell
21 Classroom Tutorial on the Design of a Cellular Manufacturing System
22 Teaming Industrial Engineers with Employees to Improve a Shipping Department
23 Implementation of JobshopLean in a Forge Shop
24 Implementation of JobshopLean in a CNC Machine Shop Appendix 1 Free Online Sources of Information on Implementing Lean in CNC Machine Shops

Appendix 2 Case Study: Implementation of JobshopLean in a CNC Machine Shop (Hardy Machine & Design Inc.)

25 Implementation of JobshopLean using a One-Cell-At-A-Time Approach

Appendix 1 Examples of Kit Carts Implemented in Different Companies

26 Educational and Training Resources for JobshopLean
  1. How to Develop a Video and Self-Study Guide on Waste Elimination
  2. Instructional Materials for the Toast Kaizen Video
  3. Instructional Materials for the Single Piece Flow© Simulation
  4. Instructional Materials for the Stamping Out Chaos© Simulation
  5. A Step-By-Step Approach for Implementing JobshopLean
  6. Instructional Materials for the JobshopLean© Simulation
27 Introduction to Value Network Mapping
  1. Value Stream Mapping: A Foundation Step for Lean Manufacturing
  2. Value Stream Mapping from an IE Viewpoint: Ideas for Enhancement and Extension
  3. Value Stream Mapping from an IE Viewpoint
  4. Evaluation of the Value Stream Mapping Icons for Use in Jobshop-type Facilities
  5. Value Network Mapping (VNM): Visualization and Analysis of Multiple Interacting Value Streams in Jobshops
  6. Value Stream Mapping of a Complete Product
  7. Integration of Lean Thinking and Theory Of Constraints in a Custom Forge Shop
28 Starter Advice for Implementing JobshopLean (Alwyn Aliwarga) From IE Graduate Student to Business Transformation Leader
Appendix 1 Informative Books on the Toyota Production System
29 The Teacher of Industrial Engineering Should Become a Student of Lean

Appendix 1 A Comparison of the IE taught in Textbooks and ToyotaIE

Appendix 2 Examples of Manual Lean Tools Enhanced with Operations Research

30 New Ideas and Tools to Build High-Mix Low-Volume (HMLV) Factories of the Future

Appendix 1 Innovative Facility Layout Design Practices Pioneered by Toyota

31 The JobshopLean Advisor

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