Teaching JobshopLean to Small andMedium Manufacturers

An Introductory Curriculum for In-House Workforce Training and Development

Like Lean, Six Sigma, TOC, Operational Excellence, etc., JobshopLean is a strategy thatis neither a panacea nor a cure-all for the problems and challenges faced by jobshops.But, it works and it easily ensures that a jobshop does not make the mistake of becomingLean by sacrificing Flexibility and Agility. The core concept underlying JobshopLean isthat of “flexibility through focus” by first and foremost re-organizing (or at least tryingto re-organize) the layout of any jobshop into flexible cells that will each produce a partfamily that exists in any jobshop’s product mix.

This set of 5 CD’s introduces JobshopLean, a strategy to adopt, adapt and enhance Leanfor any high-mix low-volume manufacturing facility. A brief description of the contentsof each CD follows:

(CD #1) Introductory Lectures on JobshopLeanFor each lecture, there is a folder containing (i) the video recording for that lecture, (ii)the Powerpoint presentation that I used for the lecture, (iii) additional files that I mayhave referenced during the lecture and, in some cases, (iv) supplemental reading for thatlecture. This is what each of these introductory lectures on JobshopLean discusses:o Overview of Lean Manufacturing: In this lecture, I talk about Lean in general,

discuss the 5-step process for implementing Lean that James Womack and DanielJones describe in their bestseller book (Lean Thinking) and lay the foundations for thenext lecture.

o What is JobshopLean? In this lecture, I present the numerous reasons why I believethat JobshopLean is different from Lean. Also, I describe a framework forimplementing JobshopLean by adapting the 5-step process for implementing Leanthat was originally proposed by James Womack and Daniel Jones.

o Essential Foundation for JobshopLean: In this lecture, I explain the “pillars” thatsupport the “House of JobshopLean”: (i) a facility layout designed using ProductionFlow Analysis, (ii) Manufacturing Cells and (ii) Group Technology.

o Quick-Start Approach for JobshopLean: In this lecture, I describe in detail anapproach that any jobshop can use to do a pilot JobshopLean project.

o Tutorial on PFAST: In this lecture, I present an overview of how the PFAST(Production Flow Analysis and Simplification Toolkit) software works and the formatrequirements for the Excel spreadsheets in a PFAST Input File. Since 2001, we havebeen using the outputs from PFAST to implement JobshopLean in manufacturingfacilities across the US!

o Patient Flow Analysis to Design a Lean Hospital: Isn’t a hospital essentially ahealthcare jobshop? In this lecture, I describe how we used Production FlowAnalysis to design a “Lean” hospital layout.

o Value Network Mapping: In this lecture, I teach a method that we developed toreplace Value Stream Mapping (VSM). VSM has numerous limitations when used toimplement Lean in high-mix low-volume non-assembly manufacturing facilities.

o Setup Reduction on a Forging Press: In this lecture, I describe how we usedProduction Flow Analysis to design the workspace around a single forging press aspart of a SMED (Setup Reduction) project.

This CD also has a folder named “Success Stories” containing presentations that describea variety of JobshopLean projects that we have done over the years.

(CD #2) A Program to Initiate JobshopLean at Bula Forge & Machine Inc.This CD should be used after you have heard my lecture on the Quick-Start Approach forJobshopLean. It contains a video based on a 3-month graduate internship that was doneto implement the Quick-Start Approach to JobshopLean in a custom forge shop.

(CD #3) How a Jobshop developed their In-House Training Video on WasteElimination

Like CD#2, this CD should be used after you have heard my lecture on the Quick-StartApproach for JobshopLean. It offers a step-by-step tutorial on how a jobshop couldincorporate a “gemba walk” into their curriculum to teach JobshopLean to employees andmanagers.

(CD #4) Jobshop Lean Simulation/GameAre you frustrated with all the Lean simulations that teach how to implement Lean inassembly facilities? The JobshopLean Simulation teaches strategies and tools toimplement Lean in a jobshop. This CD contains (i) all the game materials that you willneed to run the simulation and (ii) two video recordings that show a pre-JobshopLean anda post-JobshopLean session of this simulation/game.

(CD#5) BooksThis CD contains electronic versions of three books I have written to show how IndustrialEngineering concepts and tools can enrich and enhance the use of Lean, Six Sigma andTOC. The titles of these books are:(1) Hybrid Cellular Layouts: New Ideas for Design of Flexible and Lean Layouts for

Jobshops(2) Value Network Mapping: Extending Value Stream Mapping to enable Lean

Manufacturing in Jobshop-type Custom Manufacturing Facilities.(3) An IE Student’s Study Guide for Bottleneck Scheduling using Theory Of Constraints

Questions?If you have any questions on how this educational package could be used to teach yourworkforce and implement JobshopLean in your organization, please do not hesitate tocontact me by phone (614-688-4685) or by email (irani.4@osu.edu). Thank you!

Shahrukh IraniDepartment of Integrated Systems EngineeringThe Ohio State University

Columbus, OH 43210