Table of Contents

Foreword. Testimonial. Acknowledgments. Author. 1 About This Book. 2 Introduction to Job Shop Lean. 3 Is Job Shop Lean Right for You?. 4 Design For Flow (DFF): The Essential Foundation for Job Shop Lean. 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. 9 How Data Mining Guides Various Production Flow Simplification Strategies. 10 Improving Flow at Any Level in a Factory. 11 Industry Applications of Production Flow Analysis by IE Students. 12 Production Flow Analysis Using Metrics-Aided Visual Assessment of Material Flow Diagrams. 13 Product Mix Segmentation. 14 Determining the Correct Layout Shape for a High-Mix Machining Cell. 15 Lessons Learned from Implementing the Lean Principles in a Single High-Mix Low-Volume Make-To-Order Compressor Parts Machining Cell. 16 How Cell Formation Drives the Implementation of Job Shop Lean. 17 How to Make a Machine Shop Lean and Flexible. 18 How to Make a Custom Fabrication Shop Lean and Flexible. 19 Introduction to Operations Scheduling for High-Mix Low-Volume Manufacturers. 20 Finite Capacity Scheduling of a Flexible and Lean (FLean) Machining 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 Job Shop Lean in a Forge Shop. 24 Implementation of Job Shop Lean in a CNC Machine Shop. 25 Implementation of Job Shop Lean Using a One-Cell-at-a-Time Approach. 26 Educational and Training Resources for Job Shop Lean. 27 Introduction to Value Network Mapping. 28 Starter Advice for Implementing Job Shop Lean. Index

About the Author

Dr. Shahrukh A. Irani, PhD, is the President of Lean and Flexible, llc, a consulting company that delivers advisory, training and implementation services focused on Lean for high-mix low-volume manufacturing (aka JobshopLean). Currently, he teaches a 2-semester project-intensive course on Lean Manufacturing in the Department of Industrial Engineering at the University of Houston. From 2012-2018, he was the President of the Houston Senior Chapter of the Institute of Industrial and Systems Engineering. From 2012-2014, he worked as the Director of IE Research at Hoerbiger Corporation of America, Inc. (HCA), Houston, TX. In that position, he gained invaluable industry experience by undertaking projects to demonstrate the viability of JobshopLean in HCA’s high-mix low-volume (HMLV) manufacturing facilities. 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 research team at OSU 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. For 1999-2001 and 2001-2003, he served as the Director of the Facilities Planning and Design (FAPAD) division of the Institute of Industrial Engineers. In 1996, he was voted Young Engineer of the Year by the Minnesota Federation of Engineering Societies and the Minneapolis Chapter of the Institute of Industrial Engineers. Dr. Irani is the Editor of the Handbook of Cellular Manufacturing Systems (1999, John Wiley).