A production system for job shops

The Toyota Production System cannot overcome most of the key operational challenges typically faced by a job shop. Some of the operational challenges anyjob shop faces are: * Their product mix consists of hundreds of different products. * Product routings have different machine requirements, setup t...

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Bibliographic Details
Published in:ISE ; Industrial and Systems Engineering at Work 2022-07, Vol.54 (7), p.26-26
Main Author: Irani, Shahrukh A
Format: Article
Language:English
Subjects:
Batch production
Brand loyalty
Constraints
Control equipment
Cross-training
Customers
Cycle time
Delivery scheduling
Finite capacity
Flexibility
Job shops
Layouts
Machine requirements
Machine shops
Machining
Manufacturers
Manufacturing
Product mixes
Production scheduling
Schedules
Setup times
Ventilators
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Summary:The Toyota Production System cannot overcome most of the key operational challenges typically faced by a job shop. Some of the operational challenges anyjob shop faces are: * Their product mix consists of hundreds of different products. * Product routings have different machine requirements, setup times, cycle times, etc. * The shop layout is usually a process layout that automatically promotes batch production. * It may be difficult to identify product families in the product mix. * Demand variability is high. * Order quantities can range from one into the hundreds or thousands. * Lead times quoted to customers must be derived from the production schedule. * A production schedule must be generated to complete all orders by their due dates subject to finite capacity constraints and capacity-constrained resources ("bottlenecks") that may shift. * It is hard to control suppliers' delivery schedules and quality. * The diverse mix of equipment from different manufacturers necessitates cross-training of operators. * Customer loyalty is not guaranteed. * Different markets must be served to survive downturns. * The customer base and product mix change every year. * There are limited resources for workforce training. * Salary expectations of talented employees often cannot be met. [...]Donson Machine, a machining job shop, received no financial help from the government and used its existing machines and machine shop to add critical parts for ventilators to its product mix.
ISSN:2471-9579