[Iefac.list] [A How-To Workshop on] Design of Facility Layouts and Implementation of JobshopLean using Production Flow Analysis

[Shahrukh A. Irani]

****** A Workshop for Industrial Engineers and Lean Practitioners ******

 

Facility Layout and JobshopLean using Production Flow Analysis

 

Background

Small and medium-size manufacturers are the exact opposite of assembly line
manufacturers like Toyota.  They operate in high-mix low-volume conditions
that require them to be both Lean and Flexible.  We believe that the
foundation for being a Lean and Flexible manufacturer is a good facility
layout for achieving delay-free minimum-cost material flows.  In fact, just
about any respected book on Lean Manufacturing - Lean Thinking (James Womack
and Daniel Jones), Toyota Production System (Taichi Ohno), The New
Manufacturing Challenge (Kiyoshi Suzaki) - considers facility layout to be
an important enabler for waste elimination and delay-free material flow.
Even a basic result in queuing theory - Little's Law - relates some of the
Seven Types of Waste (WIP, queues and transportation) to the velocity of
material flows through the facility.  Unfortunately, the methods for
facility design offered by Toyota (Value Stream Mapping, Physical Mock-ups,
Spaghetti Diagrams, 5S) and modern textbooks (From-To Charts, Relationship
Charts, Mathematical Programming) are cumbersome and/or inapplicable and/or
impractical in the real world.  

 

Objective

This workshop will present proven ideas, methods and software tools for
designing both Lean and Flexible facility layouts for high-mix low-volume
multi-product multi-machine manufacturing facilities.  It will show how to
integrate facility design strategies pioneered by Toyota with new software
based on the method of Production Flow Analysis (PFA) developed in the early
1970's.     

 

Agenda

If you wish to receive an electronic copy of the agenda, please email me at
irani.4 at osu.edu or call me at (614) 688-4685.  

 

Benefits for Industry Practitioners

.            Adapting and enhancing the standard Lean best practices for the
more challenging case of high-mix low-volume multi-product multi-machine
manufacturing facilities 

.            Replacing manual methods, such as Value Stream Mapping and Flow
Diagrams, with more effective computer-aided methods that can handle a
product mix with 250-500 (or even more) different manufacturing routings

.            Building a new facility and wish to get the facility layout
correct at the outset

.            Re-arranging/expanding the existing facility

.            Re-locating the existing facility into another building

.            Purchasing flexible manufacturing equipment to replace 2-3
existing machines

.            Installing a flexible manufacturing cell and wish to identify a
family of parts that could potentially be produced in this cell 

.            Determining how to diversify and rationalize the product mix
without introducing chaos and complexity into current operations

 

Free Assessment Offered to Industry Practitioners

If you are with a manufacturing company and want to know whether you should
attend this workshop, I could email you a one-page assessment.  Please fill
it up and fax it back to me at (614) 292-7852 with a phone # that I could
reach you at.  I will get back to you with a quick assessment and
recommendation whether attending this workshop is worth your time and money.

 

Benefits for Industrial Engineering (IE) Faculty

.            Discover how Lean enriches textbook theory on facility layout

.            Evaluate new "revisionist" theory on facility layout that was
inspired by Lean, especially algorithms that use routings (or an entire Bill
Of Routings for a large product) as input instead of From-To Charts

.            Evaluate PFAST (Production Flow Analysis and Simplification
Toolkit) as a front-end software to complement standard block layout
software for facility layout

.            Link facility layout and material flow to problems in
Manufacturing Engineering, such as selection of flexible automation, process
planning, product mix rationalization, etc.

.            Obtain lectures on facility layout that contain case studies
and exercises derived from numerous industry projects 

 

Dates

March 16-17, 2009

 

Location

Room 281, Baker Systems Engineering, The Ohio State University, Columbus, OH
43210

http://www.osu.edu/map/building.php?building=280 

 

Software Requirements

While our laboratory computers in BE281 have PFAST and STORM installed on
them, you are encouraged to bring along your laptop with these two software
packages (or any other block layout software, such as SPIRAL, CRAFT,
BLOCPLAN, etc.) installed on them.  Here is how you could obtain the two
software packages that will be used for this workshop:

1.      Demo version of PFAST: Send me a blank CD in a self-addressed
mailer.  Else, if your email system will allow attachments containing .exe
files, send me an email at irani.4 at osu.edu and I will send you the program
files as an attachment.

2.      Student version of STORM (with manual): It is available for purchase
at http://www.directtextbook.com/editions/hamilton-emmons-storm-4-0 or
http://www.crowncustompublishing.com/cgi-bin/commerce.cgi?cart_id=1130078929
.19593
<http://www.crowncustompublishing.com/cgi-bin/commerce.cgi?cart_id=113007892
9.19593&product=Books&pid=32> &product=Books&pid=32).  However, the
out-of-print book - Emmons, H., Flowers, A.D., Khot, C.M. and Mathur, K.
(2001). STORM 4.0: Quantitative Modeling for Decision Support. Euclid, OH:
Lakeshore Communications - is a superior self-study manual for using this
software.

Since the demo version of PFAST is free and the student version of PFAST
costs less than $100, I love this cheap but functional toolkit for teaching
facility layout and executing industry projects!

 

Registration Fee

$150 per person payable by check to "The Ohio State University".

 

Logistics

Attendees are responsible for making their own travel and hotel
arrangements.

 

A Special Bonus for Attendees

You could also attend the JobshopLean Simulation on March 18 at no extra
cost!  This simulation is essentially a manual interactive game that uses a
hypothetical multi-machine multi-product jobshop to demonstrate a variety of
JobshopLean best practices that have been proven to work in practice.  In
particular, it demonstrates how to put into practice the ideas, methods and
software tools that will be discussed in the workshop.  

 

This event is being sponsored by Manufacturing Engineering Inc.
(www.mfgeng.com) and will be conducted at their corporate offices.  For
further information on this event, please email Jerry Hoskins at
Hoskins at mfgeng.com or call him at (614) 487-7900 x103.     

 

Questions?

If you have any questions, please email me at irani.4 at osu.edu or call me at
(614) 688-4685.

 

Thank you.  

 

Shahrukh A. Irani

Department of Industrial, Welding and Systems Engineering

The Ohio State University

Columbus, OH 43210

 

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