November 6-7, 2017 | 8 a.m. - 5 p.m.
INTRODUCTION TO THE WORKSHOP
The core of this workshop is Lean. Lean is based on the Toyota Production System (TPS). This highly sought after management model has been adopted successfully by many industries. Lean organizes manufacturing and logistics to design out overburden and inconsistency while reducing waste. Waste can be in several forms such as overproduction, time, transportation, processing, movement, defective products, and under-utilized workers.
Originally, the TPS was designed for low-mix high-volume (LMHV) product assembly. However, in this workshop we will show you how to modify and adapt it to your HMLV (high-mix low-volume) manufacturing process. Examples of high-mix low-volume (HMLV) component manufacturers are:
- any forge shop
- any machine shop
- any fabricator
- any Make-To-Order product fabricator
- any repair facility
- any foundry
This workshop will teach JobshopLean, a modified approach to implement the same Principles of Lean (Source: www.lean.org/WhatsLean/Principles.cfm). JobshopLean utilizes Industrial Engineering practices and methods inspired by the simple, intuitive and proven methods of the Toyota Production System. However, instead of relying on the cumbersome manual methods and tools of Lean, JobshopLean uses computer-aided solution approaches to overcome the challenges of implementing Lean in high-mix low-volume facilities. JobshopLean focuses on the following strategies:
- reduction of the three wastes (Transportation, WIP and Waiting) that destroy Cash Flow Velocity
- product mix segmentation into part families
- shop floor layout reorganization into manufacturing cells
- team-based employee engagement in each cell
- management involvement in the operations of the cells
An attendee should (a) be working for a high-mix low-volume manufacturer, (b) be reasonably conversant with Lean (as based on the Toyota Production System) and (c) have prior experience in implementing Lean. Examples of high-mix low-volume manufacturers would be those that have SIC (Standard Industrial Classification) codes such as 20xx, 23xx, 24xx, 25xx, 31xx, 34xx, 35xx, 36xx, 37xx, 38xx and 39xx. In addition, this workshop has valuable takeaways for industry professionals with the following job titles:
- Business Owner/President
- VP – Operations
- Director – Operations
- Operations Manager
- Engineering Manager
- Plant Manager
- Facility Planner
- Manufacturing Engineer
- Industrial Engineer
- Production Supervisor
- Lean Six Sigma Practitioner
- Lean Champion
Dr. Shahrukh Irani | Bio
President, Lean and Flexible, llc
4102 Pensacola Oaks Lane
Sugar Land, TX77479
Learn more: Online Study Guide
If you have questions about how this workshop will apply to your manufacturing environment, please send an email to the Instructor at ShahrukhIrani1023@yahoo.com or call him at 832-475-4447. The instructor can also give you an honest assessment whether the workshop will benefit your company if you would complete a one-page questionnaire and return it to him at the above address. Alternatively, he could recommend some of the articles on LinkedIn that will provide more background information on JobshopLean.
RESULTS REPORTED BY CLIENTS WHO IMPLEMENTED JOBSHOPLEAN
- In the news: Read Lean Manufacturing Begins With Layout, Commitment in the July 2017 issue of Modern Machine Shop Online. The article features work that Dr. Irani did with the team at Wear Technology Inc. to implement JobshopLean in their CNC machine shop.
- Weber Metals (Los Angeles, CA) reported a one-time work-in-progress (WIP) inventory avoidance of $3,000,000 after implementing the proposed shop re-layout and scheduling strategy
- TECT (Cleveland, OH) reduced floor space requirements with their new layout which reduced their annual facility leasing costs by $350,000
- TECT (Cleveland, OH) estimated that their new layout reduced travel time for forgings produced for a key customer by ≈ 85%
- Ulven Forging (Hubbard, OR) implemented a new layout and invested in new equipment that resulted in an annual savings of $137,000
- Ulven Forging (Hubbard, OR) reduced the average time it took their front office to respond to an RFQ from 10.2 days to 2.4 days
- SIFCO Forging Industries (Cleveland, OH) implemented a work cell in their Non-Destructive Testing department that increased Equipment Uptime by 20% and increased Labor Productivity by 10%
- Bula Forge & Machine Inc. (Cleveland, OH) reorganized their Shipping Department which eliminated excess work-in-process (WIP) valued at ≈ $130,000
- G&G Mfg. Co. (Cincinnnati, OH) implemented a flexible flow cell that reduced Manufacturing Lead Time for a representative part from 12 working days to 5 working days
- Alpha 1 Induction Service Center (Columbus, OH) implemented a work cell that yielded a first year’s cost savings of $64,000
- Hoerbiger Corporation of America (Houston, TX) estimated that implementation of a machining cell would (1) reduce order fulfillment time from 16 days to 5 days and (2) reduce annual material handling labor by 51 hours
- Hoerbiger Corporation of America (Houston, TX) implemented a new layout for their Shipping Department with ≈ 50% less floor space requirements
- Hirschvogel Inc. (Columbus, OH) reduced setup time on one of their cold forging presses fro m125 minutes to 94 minutes which enabled an estimated increase in annual production valued at $300,000
WORKSHOP STRUCTURE AND MATERIALS
Each attendee is responsible for bringing their own materials, such as pens, paper and computers. The Instructor will provide the course notes for the workshop and all materials relevant to each of the different exercises, simulations, etc.
- How JobshopLean Adapts and Extends Lean for High-Mix Low-Volume (HMLV) Manufacturing
- Flow: The Essential Foundation for Implementing JobshopLean in any Factory
- Fundamentals of Waste Identification and Elimination
- Manufacturing Cells: How to Design, Operate and Manage Product-focused Teams
- SIMULATION - Design and Operation of a Stamping Cell
- CASE STUDY - Lessons Learned from Implementing Lean in a Compressor Parts Machining Cell
- OPEN FORUM - Is JobshopLean Right For You?
- SIMULATION - JobshopLean Practices for High-Mix Low-Volume Custom Products Manufacturing
- Sequencing Jobs Through a Flowline Cell
- Scheduling a Manufacturing Cell with Finite Capacity Constraints
- How Do You Get Started with JobshopLean At Your Place of Work?
If you would like to receive the detailed Agenda for the workshop, please send an email to the Instructor at ShahrukhIrani1023@yahoo.com or call him at 832-475-4447.
WORKSHOP LEARNING OUTCOMES
- Attend a workshop that teaches valuable concepts and methods for high-mix low-volume Walk away with a clear vision that JobshopLean blends the best operational practices learned from Group Technology, Cellular Manufacturing, Industrial Engineering, Toyota Production System, etc.
- Learn how to use Production Flow Analysis (instead of the manual method of Value Stream Mapping) for implementing Lean in any high-mix low-volume manufacturing facility
- Refresh your skills at identifying waste on the shop floor using a Spaghetti Diagram, Value Stream Map and Process Analysis
- Study the inner workings of an actual manufacturing cell that uses Lean practices such as Quality-At-Source, Total Productive Maintenance, Poka-Yoke, 5S, Teamwork, Cross-Functional Training Boards, Ergonomics, etc.
- Participate in an interactive simulation that tests your academic knowledge and work experience on how best to transform the layout of a machine shop to become Lean and Flexible (FLean)
- Participate in an interactive simulation that teaches operational strategies for a manufacturing cell
- Participate in an interactive simulation that teaches operations scheduling for a manufacturing cell
- Participate in two discussions with all attendees (1) Is JobshopLean Right For You? and (2) Where Do You Go From Here?
- Learn to collaborate extensively with one or more top-ranked Industrial Engineering programs because every HMLV manufacturer must develop a production system that is best suited to their operations!