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

743 Pages·2020·155.012 MB·English
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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

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