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Lean Manufacturing for Job Shops
"Lean Manufacturing" is a great way to make your company better, faster, and more profitable.  It works great for assembly lines.  It works great for semi-repetitive cells.  But what about a job shop?
By Robert J. Tristani and Shahrukh A. Irani
"Lean Manufacturing for Job Shops" is more than just a book.  It is a complete package designed to get you well on your way to implementing the princples of Lean Manufacturing in your job shop. 
Included in the package is the text "Lean Manufacturing for Job Shops," a CD about "Value Network Mapping," and a DVD titled "How a Jobshop Developed their In-House Training Video on Waste Elimination." 
Click here for publisher's website to buy the package
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Rob Tristani
What You Will Learn from this Package:
Selections from the Package:
Shahrukh Irani
What is a Job Shop and why it is different from a "Lean Implementation" standpoint.

How and why to set up shop performance metrics in a shop with irregular work-center-to-work-center routings, and varying work content.

How to use similar metrics to compare shop performance on dissimilar jobs.

How to troubleshoot shop performance with the metrics.

The relationship between inventory and lead time (Little's Law) and how to use it in a non-steady-state job shop where routings, WIP, and work content are always changing.

How to use a "Value Network Map" instead of a "Value Stream Map" in a non-steady-state shop.

How and why to set up a "Work Release System" in a shop with unsteady demand and irregular routings and dissimilar work content.

How to use the "Theory of Constraints" in a shop where the constraint is always changing.

What are some of the assumptions of the "Conventional Lean" Toyota Production System, and why they are invalid in a job shop.

How to implement Lean in a "Project Manufacturing" shop such as satellite or large control panel construction.		 Definition of a Job Shop
About the Authors: Problems using a Value Stream Map in a Job Shop
Robert Tristani is a Manufacturing Engineer at a large shipyard.  He has assisted with improvements in Pipe Shops, Machine Shops, Sheet Metal Shops, a Foundry, and every type of shipboard outfitting shop imaginable.
More about the Package:
The book itself has two parts that are intertwined within each other.  The first part is an in-depth "textbook" discussion on how to implement Lean Manufacturing in a job shop.  Interspersed within the chapters of the textbook is the story of Southern Foundry and Pattern Works, a fictitious foundry implementing the principles taught in the textbook portion.  This style of writing both teaches the principles and also shows  examples of how they can be implemented.

The CD about "Value Network Mapping (VNM)" teaches how to set up and use a VNM.  A VNM is a valuable tool for identifying required areas and benefits for future states.  It is specifically designed for use in a job shop, and solves the problems that arise from using the Value Stream Map in a non-repetitive environment with hundreds, or even thousands of value streams that share resources.

Also included is a DVD on how a particular real-world job shop began their Lean journey using the principles personally taught to them by Dr. Irani.  Also on this disc is a video presentation titled "Toyota Lean vs. Jobshop Lean" that shows how some of the basic assumptions of the Toyota Production System are not valid in a Job Shop, and how the Toyota Lean tools must be modified or replaced for job shop implementation.
Dr. Shahrukh Irani is an Associate Professor of Industrial and Systems Engineering at Ohio State University.  He is a prolific author, specializing in Lean for job shops.  He is the forefront of academic thinking for the application of Lean in non-repetitive high-mix low-volume facilities.
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