Job shops are a manufacturing system where the machines are not arranged in the sequence of the work steps (as in a flow line). Rather, the flow of the part conforms to the arrangement of the machines.
There are different ways to organize your shop floor. You surely know the flow shop and the job shop. There is also a project shop (with many variants of names). While the flow shop is in many cases the ultimate goal, each shop has advantages and disadvantages. Let’s look at them in more detail, starting with the project shop. Continue reading Organize Your Production Sequence – 1: Project Shop→
Lean is my life. Whenever I see someone working, I cannot help but to think about the work from a lean point of view. Every now and then I come across a little gem, where I am just thoroughly impressed with someone’s approach to manage and improve their work. During my winter vacation in Iceland, I came across just such a gem with an excellent corporate culture for continuous improvement. Let me introduce Te & Kaffi and its lean mindset. Continue reading The Lean Mindset – Te & Kaffi in Iceland→
Japan is a wonderland for anybody interested in lean. Of course there is the archetype of lean manufacturing, the Toyota group and its Toyota Production System. However, access to Toyota plants is restricted, and during their guided tours you can observe only so much. (See for example my post on Evolution of Toyota Assembly Line Layout – A Visit to the Motomachi Plant as the result of such a tour).
There are different ways to manage workers in an manual U-line. One of these methods is known as the “Rabbit Chase,” also known as the “Caravan Approach” or “Operators-in-Motion.” The workers always move in a circle and handle all processes in sequence. Continue reading The Lean Rabbit Chase in a U-Line→
Exactly 150 years ago, on February 14, 1867, Sakichi Toyoda (豊田 佐吉 Toyoda Sakichi) was born. He is known in Japan as the King of Inventors (which is probably a bit of an exaggeration), father of the Japanese Industrial Revolution, and also the founder of the Toyota industrial empire. Time to take a look back in history on his life. Continue reading 150th Anniversary of the Birth of Sakichi Toyoda→
Chaku Chaku is a way to operate a semi-automated manufacturing line. One (or more) workers walk around the line, add parts to the processes, and then start the process. While the process works on the part automatically, the worker adds the next part to the next process, and so on. Continue reading The Chaku Chaku Line→
This is the third and final post on lot sizes (Part 1 and Part 2). After considering all the factors of the processes and inventories (changeover time, batch size, customer order size, and container and shipment size), we now look at how to set up the information flow. This is especially important if we want to have different lot sizes in different sections of our value stream. Continue reading How to Determine Your Lot Size – Part 3→