The
Introduction of Lean in Jobshops educational package brings together at least ten years of work to develop and validate a computer-aided approach to implement Lean in jobshops! Despite the proven power and universal applicability of the methods and tools of the Toyota Production System, when it comes to implementing Lean in jobshops, there is an alternative computer-aided approach JobshopLean that directly (and correctly) addresses the challenges of making any jobshop Lean
and Flexible
and Agile. This educational package brings together at least ten years of research at The Ohio State University to develop and validate this computer-aided approach to implement Lean in jobshops that is founded on Production Flow Analysis and Group Technology. This package contains the following educational/training products:
Study Plan for this Educational Package
Now that you have opened it, I am sure that the very first question on your mind is, Hmm, so which of these five products do I study first? Well, everything depends on whether you are already well-versed in Lean, Facility Layout, and the two software packages
PFAST (Production Flow Analysis and Simplification Toolkit) and
STORM . Therefore, I offer to you a study plan that consists of the following sections. Each section guides you to the appropriate content derived from the five products that comprise this educational package:
- Learning the Fundamentals of JobshopLean
- Learning the Fundamentals of Facility Layout
- Learning to Use PFAST and STORM to Implement the Lean Advisory Tools (LAT) for Jobshops
- Learning to Use PFAST and STORM for Design of Facility Layouts using Production Flow Analysis
I hope that, when you are done learning all that you can from this educational package, you will agree that there is invaluable benefit to be gained by using Production Flow Analysis and Group Technology to (i) implement Lean in jobshops, AND (ii) design suitable shop layouts for these facilities to make them Lean and Flexible and Agile.
Learning the Fundamentals of JobshopLean:
Load into your computer the CD titled
JobshopLean and Facility Layout using Production Flow Analysis and read the presentation (March 16, 8:00 8:30 a.m.,
JobshopLean versus ToyotaLean: Adopting, Adapting and Enhancing the Toyota Production System for Jobshops in the 21st Century).
Next, if you desire more background information on JobshopLean, study the following documents in the section Additional Resources for this Workshop on the same CD:
- Recession-Proof your Shop the Lean Way.
- Inaugural Issue of JobshopLean Journal.
- Case Studies on Lean in Jobshops.
Next, on the same CD, read the presentation (March 17, 1:00 2:00 p.m.,
Results and Experiences from Implementing the Quick-Start Approach for JobshopLean in a Custom Forge Shop).
Next, if you want more information about my Quick-Start Approach for (Implementing) JobshopLean, then open the folder named
Quick-Start_Approach_For_JobshopLean to read the presentation on my approach. In the sub-folder named
Hyperlink Files, you will find examples of some of the key worksheets that my approach uses.
Finally, if you are interested in industry projects done by students that are based on the Quick-Start Approach for JobshopLean, then you may want to read the other two presentations on the workshop CD:
March 17, 2:00 -2:45 p.m.,
A Graduate Industrial Engineering Course that Integrates Lean and Manufacturing Systems Engineering
March 17, 3:00 3:45 p.m.,
An Undergraduate Industrial Engineering Course that Integrates Lean and Facility Layout
Next, see the video about the implementation of the
Quick-Start Approach to JobshopLean at Bula Forge & Machine, Inc. on the DVD titled
A Program to Initiate JobshopLean at Bula Forge & Machine Inc. that is included in this educational package.
Finally, to receive a self-paced step-by-step tutorial on the process I use to help any jobshop begin their Lean Journey, use the other DVD titled
How a Jobshop developed their In-House Training Video on Waste Elimination that is included in this package. This DVD contains a folder (Folder Name: FILES) and a Word file (File Name: STARTHERE_HowToDevelopTheTrainingVideo.doc). In the Word file, a section has been devoted to describe each of the following steps in the process that I execute. Each section ends with one or more files in different formats (.doc, .ppt, .pdf, .wmv, etc.) that provide the complete details about that step. If you click on the hyperlink to that file, it will automatically load/run. This process that I use ensures that the employees and managers of any jobshop will thoroughly understand and master my Quick-Start Approach for JobshopLean!
Learning the Fundamentals of Facility Layout:
Begin by studying from cover-to-cover the book titled
Hybrid Cellular Layouts: New Ideas for Design of Flexible and Lean Layouts for Jobshops that is included in this package. Alternatively, if you want a quick overview of Production Flow Analysis, Cellular Manufacturing and the nexus between Facility Layout and JobshopLean, then load into your computer the CD titled
JobshopLean and Facility Layout using Production Flow Analysis and read the presentation (March 16, 8:30 9:00 a.m.,
The Essential Foundation of JobshopLean in any Factory: Reduction and Simplification of Material Flows).
Next, try to implement the methodology described in the presentation (March 16, 9:00 9:45 a.m.,
LEAN 101: Waste Identification and Assessment of Production Flows in any Existing Facility Layout using a Spaghetti Diagram and a Facility Walkthrough).
Learning to Use PFAST and STORM to Implement the Lean Advisory Tools (LAT) for Jobshops:
I use the workbook
Lean Advisory Tools for Jobshops that is included in this package for the annual workshop that I offer on how to implement Lean in jobshops using PFAST and STORM. Please forgive me if I concede that, in order to fully understand each LAT (Lean Advisory Tool), it may be necessary for you to attend that workshop. So, if you do plan to attend the next one, be sure to bring this workbook along! Alternatively, if you want a quick overview of the current suite of LATs and a flowchart that shows the typical sequence in which to use them to facilitate Lean in jobshops, then load into your computer the CD titled
JobshopLean and Facility Layout using Production Flow Analysis and read the presentation (March 17, 8:00 9:15 a.m.,
How to Simplify any Jobshop using Part Families and Cellular Manufacturing).
Learning to Use PFAST and STORM for Design of Facility Layouts using Production Flow Analysis:
If possible, try to obtain a copy of this seminal book Burbidge, J.L. (1996).
Production Flow Analysis for Planning Group Technology. New York, NY: Oxford University Press Inc. ISBN 0-19-856459-7 and learn/understand the basics about each of the 5 phases of Production Flow Analysis.
Next, load into your computer the CD titled
JobshopLean and Facility Layout using Production Flow Analysis and read the following presentations:
- March 16, 10:00 10:45 a.m., Product Mix Segmentation: How to Identify the Critical Value Streams in a Jobshop with Hundreds of Unique Part Numbers
- March 16, 10:45 11:15 a.m., Factory Flow Analysis (FFA) using PFAST
- March 16, 11:15 a.m. Noon, Group Analysis (GA) using PFAST (Part 1 of 2): Feasibility Analysis for Independent and Stand-alone Cells
- March 16, 1:00 2:00 p.m., Group Analysis (GA) using PFAST (Part 2 of 2): Design of Flexible and Lean Layouts for any Jobshop when Independent and Stand-alone Cells are Infeasible
- March 16, 2:00 3:00 p.m., Line Analysis (LA) using PFAST
- March 16, 3:00 4:00 p.m., Tooling Analysis (TA) using PFAST
- March 16, 4:00 4:30 p.m., Tooling Analysis (TA) using Group Technology (GT)
- March 17, 10:45 a.m. Noon, Value Stream Mapping of a Complete Product (=Value Network Mapping)
Once again, please forgive me if I concede that, in order to fully understand my methods, it may be necessary for you to attend the annual workshop that I teach titled
JobshopLean and Facility Layout using Production Flow Analysis. If you do plan to attend the next one, be sure to bring the complete educational package along.
Perhaps the best way to learn my methods is to jump right in and implement the Quick-Start Approach for JobshopLean in your facility!
