After two post on the basics and workshop structure, I can finally start to go into the details of which questions to ask for design for manufacturing (DFM). In subsequent posts I will have more questions on design for assembly (DFA), which can of course be combined into design for manufacturing and assembly (DFMA). I will also have a brief refresher on creativity techniques. Let’s start asking questions!
Design for Manufacturing and Assembly Workshop Preparation
Design for manufacturing (DFM) and design for assembly (DFA) or its combination, design for manufacturing and assembly (DFMA), as well as its many design for X variants are a way to improve a design beyond its mere functionality. In my last post I gave you a basic introduction. This post will look at the prerequisites for organizing a design for X workshop. Subsequent posts will look at the different questions you can ask to further design for manufacturing and assembly.
Read moreDesign for Manufacturing and Assembly Workshop Preparation
Design for Manufacturing and Assembly Basics
Lean is most often associated with production. However, it can also be used in other areas, like design. Bridging the gap between design and production is design for manufacturing or design for manufacturability (DFM) and design for assembly (DFA), often combined into design for manufacturing and assembly (DFMA). Lean can also be combined with lesser-known topics like design for inspection (DFI) or, more recently, design for additive manufacturing (DFA). There are many more. Let me give you an introduction to the reasoning behind design for manufacturing and its “Design for X” variants before going into more details on how to do it in subsequent posts.
How to Convert a Job Shop into a Flow Shop – Part 2
Turning job shops into flow shops is not easy. This is my second post explaining such transformations as I try to help you in improving your shop floor from an (always) messy job shop into a much more efficient flow shop.
Read moreHow to Convert a Job Shop into a Flow Shop – Part 2
How to Convert a Job Shop into a Flow Shop – Part 1
Job shops are always very difficult to manage. As I described in my previous posts, the irregular material flow causes fluctuations that are very hard to contain. In my view, the only true fix for a job shop is to convert it into a flow shop. In this post I will talk a little bit about how you approach the idea of converting a job shop into a flow shop … although this is not always possible. However, in many cases it is possible to increase flow-shop-like segments, even though the whole system is still a job shop.
Read moreHow to Convert a Job Shop into a Flow Shop – Part 1
Why Are Job Shops Always Such a Chaotic Mess? Part 2
Job shops are a mess. Period. The increased and uneven levels of inventory cause a host of other problems. In my last post I described how these inventory imbalances are caused by irregular material flow, how subsequent safety buffers increase inventory even more, and how this causes staff to change their workplace irregularly in a job shop. In this post I will continue the long list of ills in a job shop with staff changeover losses, extra searching and organizing, fluctuating lead times, and general un-plannability of job shops.
Read moreWhy Are Job Shops Always Such a Chaotic Mess? Part 2
Why Are Job Shops Always Such a Chaotic Mess? Part 1
Job shops have a strong tendency toward chaos. Even well managed plants struggle to maintain order in a job shop. This is due to the inherent nature of a job shop, and there are no good solutions to manage job shops. The only good way to improve a job shop is to turn it into a flow shop. I will talk more about such changes later in this short series, but first let me explain why job shops are always a mess.
Read moreWhy Are Job Shops Always Such a Chaotic Mess? Part 1
How to Conduct a Shop Floor Meeting
In this last post (for now) on my series on shop floor management I will talk about how to conduct a shop floor meeting. Who should be there; when, how long, and how often you should have such a meeting; and what is on the agenda. I will also talk about common mistakes that you should avoid.