Job Shop Lean: An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems, 1st Edition (Paperback) book cover

Job Shop Lean

An Industrial Engineering Approach to Implementing Lean in High-Mix Low-Volume Production Systems, 1st Edition

By Shahrukh Irani

Productivity Press

560 pages | 60 B/W Illus.

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Paperback: 9781498740692
pub: 2020-05-21
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Job Shop Lean integrates techniques from the Toyota Production System (TPS) that apply to high-mix low-volume with the science of Group Technology and Cellular Manufacturing (GT/CM) to replace those parts of the TPS that pertain solely to high-volume, repeatable processes. GT/CM is the technical solution to Lean for high-mix low-volume. Toyota provides the tools to sustain GT/CM, especially the workforce culture and Lean leadership aspects.


This informative book:


  • Tackles a subject about which there is no effective book on the market that covers all the important aspects (e.g., concepts, tools, software, real success stories, etc.).
  • Teaches a method/approach (Group Technology and Cellular Manufacturing) that Toyota did not pioneer but was proven to work simultaneously that Ohno (and Toyota) were pioneering the Toyota Production System.
  • Shows how computer-aided problem-solving and IT-aided implementation of the Lean tools actually works in practice.
  • Covers advanced topics such as scheduling, IT-aided problem solving, and flexible automation.

Table of Contents

1 Introduction to this Book. 2 Introduction to JobshopLean. 3 Is JobshopLean Right For You? 4 Design For Flow (DFF): The Essential Foundation for JobshopLean. 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 JobshopLean. 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 JobshopLean in a Forge Shop. 24 Implementation of JobshopLean in a CNC Machine Shop. 25 Implementation of JobshopLean using a One-Cell-At-A-Time Approach. 26 Educational and Training Resources for JobshopLean. 27 Introduction to Value Network Mapping. 28 Starter Advice for Implementing JobshopLean. Appendix A. Appendix B. Appendix C. Appendix D. Appendix E. Appendix F. Appendix G. Appendix H. Appendix I. Appendix J. Appendix K. Appendix L. Appendix M. Appendix N. Appendix O. Appendix P.

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 Yearby 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).

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
BUSINESS & ECONOMICS / Purchasing & Buying
BUSINESS & ECONOMICS / Industrial Management