Category Archives: Material Flow

How to Convert a Job Shop into a Flow Shop – Part 1

Ford Motor Assembly 1917
Ford motor assembly with moving conveyors 1917

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. Continue reading How to Convert a Job Shop into a Flow Shop – Part 1

Why Are Job Shops Always Such a Chaotic Mess? Part 2

Ford Piston Shop 1917
Ford piston shop 1917

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. Continue reading Why Are Job Shops Always Such a Chaotic Mess? Part 2

Why Are Job Shops Always Such a Chaotic Mess? Part 1

Ford Crankshaft Shop 1917
Ford Crankshaft Shop 1917

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. Continue reading Why Are Job Shops Always Such a Chaotic Mess? Part 1