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Developing a strategy for implementation of lean concepts in job shop environments with a blend of QRM, lean manufacturing, and TOC / Gregory G. Hug.

by Hug, Gregory G.

Production mangement.

Production scheduling

Manufacturing cells.

Theory of constraints (Management)

208 leaves : ill. ; 29 cm.

Thesis advisor(s): Michael Ostregna.

Committee members: Dr. Bruce Thompson, Mark Treager.

Introduction -- SPI history and products -- Types of manufacturing environments -- Job shop environments -- What is Lean? -- Main types of Lean - Quick response manufacturing (QRM) - Just in time (JIT) - Toyota production system (TPS) - Theory of constraints (TOC) - Six sigma -- Push versus pull MRP systems for manufacturing -- Lean systems for the job shop -- SPI comparisons and differences to job shop and standard assembly -- How could the small manufacturer/job shop benefit from Lean? -- Expected organizational gains -- Interviews of organizations utilizing Lean -- Recommendations: what is the best "Lean" choice for SPI? -- Implementation plan for SPI -- Conclusion.

The thesis defines what Lean Manufacturing is and recommends a Lean strategy that should be implemented for job shop type environments with a wide variety of product offerings and mixed volumes. From the research and practical applications in use today, the data describes what Lean initiatives are best suited for this type of manufacturing environment. In manufacturing settings where wide variety, low volumes, and unpredictable product mix occur the standard Lean principles and concepts do not conform to the "normal" job shop environments. The thesis proposes a strategy and demonstrates how lean can be adapted successfully to the unique job shop/small manufacturer environment. Several job shops/small manufacturers utilizing "Lean" concepts will be analyzed to determine what principles and methods create success and failures.

Applying a mix of onventional Lean principles, Quick Response Manufacturing (QRM) and Theory of constraints (TOC) methodologies can provide the solution to meeting the organizational goals. Additional research is presented for successful implementation and the improvements in throughput. The thesis strongly recommends total organizational support to follow the process described by QRM, Lean Manufacturing, and TOC for successful implementation.

From the information gained, the applications will be applied to SPI (Service, Performance, and Innovation) Lighting. SPI, located in Mequon, Wisconsin, is a manufacturer of indirect lighting for custom lighting products. Typical applications are light fixtures in shopping malls, churches, schools, and industrial locations. What is unique about the product offerings at SPI are the low products volumes and the unlimited varieties a customer can have. SPI also builds products to suit individual customer needs in a build-to-order environment.

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