This book is an excellent resource for applying lean principles to the complex topic of highmix, lowvolume manufacturing, and is core reading material for those implementing a lean manufacturing system in this environment. What ever volume you think wouldnt overpower you hearing someone else comment on the mix. Efficient material allocation in highmix lowvolume manufacturing article pdf available in journal of advanced manufacturing systems 92 february 2010 with 1,409 reads how we. Excelling in a highmix, lowvolume environment by lane, greg and a great selection of related books, art and collectibles available now at. Low volume manufacturing often appears contrary to lean methodologies, though if you look at the toyota production system which had some of its roots in a job shop, but instead became famous for the remarkable results in high volume manufacturing plants, one must return to the principals not the high publicized tools to better understand its correct application in high mix, low volume. Principles of lean for highmix lowvolume manufacturing. Toyota production system methods have rendered remarkable results in high volume manufacturing plants, but they have not been fully understood and correctly applied in high mix, low volume environments. This comprehensive book is a musthave for plant managers, manufacturing managers, and lean practitioners who need to apply lean principles effectively in their job shops, remanufacturerepair, and highmix, lowvolume plants. We had struggled to implement a pull system for our highmix, lowvolume products. However, it can be utilized in low volume and high mix production by means of an adapted leveling approach presented in. Made to order lean excelling in a high mix low volume. Jun 10, 20 the navy needs the highlow mix across the spectrum of tactical mission areas, but how can this best be achieved. Designing high mix low volume production lines youtube. Therefore, leveling is predominantly used in high volume production.
He provides an interesting narrative of how he approaches the business and uses data and visual boards to create a lean culture. While lean principles do apply, the implementation methods and tools must be adapted and alternate methods embraced in a low volume environment. However, we feel that a better understanding of how to bias the data inputs allows for a consistent improvement in forecast accuracy. This book helps tackle that stigma and is a great tool for justifying change to upper management. By following these five steps, a process will become very consistent, despite changing product requirements. High mix, low volume processes are types of processes in which a high variety of finished goods are produced in relatively low amounts. Mahoney discusses strategic degrees of freedom, kan ban cards, the evolution of highmix, lowvolume manufacturing, the theory of constraints, manufacturing. Configured to order engineered to order technology evolution as competitive factor. For example, highvolume manufacturers win business based primarily on the cost and quality of their products, says r. The thing to consider, is just like in machining, whether youre going to do quick change vises or other workholding, youve got to make the same considerations for the end of your robot, said john lucier, automation manager at methods machine tools. It is commonly employed when practically make to stock and continuous production is performed. The production control system for high mix, low volume and custom products in which suri describes a practical approach to polca to maximize production efficiency, reduce wip work in process and prevent bottlenecks from forming. This comprehensive book summarizes critical competitive strategies, manufacturing.
This book is an excellent resource for applying lean principles to the complex topic of highmix, lowvolume manufacturing, and is core reading material for. Lean manufacturing kaizen methodology lean fastcap style. This is a true how to book for implementing lean concepts into low volume high mix manufacturing. Helping to pragmatically reach day to day and break through objectives by introducing proven methodologies to deal with the soft as well as tactical issues. In this book, manufacturing fundamentals are reexamined in a way that often gets overlooked by corporate strategists. In march 2018 rajan suri published the practitioners guide to polca. Jan 19, 2009 for the low volume high mix manufacturer, supply chain optimization requires innovative approaches to match the performance demonstrated in high volume low mix environments. Lessons from the gemba volume 1 is a collection of stories and case studies about applying lss to notforprofit organizations. During his time as an independent consultant, greg purchased and operated his own manufacturing company, which specialized in fast turnaround on high mix, low volume parts. Lowmix highvolume production production planning mrp. Michael mahoney carefully details a variety of manufacturing issues and topics that directly impact competitors in the highmix, lowvolume manufacturing arena. In 1998, he began to focus his lean endeavors on meeting the specific needs of high mix, low volume enterprises. Ten tips for maintaining quality in a highmix environment.
This book is a thorough reference for practitioners and academics interested in how manufacturing should and can be run. Applying lean manufacturing principles to optimize the supply. Cetec erp is a good fit for high mix, low volume environments, with solutions for custom manufacturing, precise tracking of production processes and thousands of inventory skus, engineering requirements, and changing customer demands. Managing material in a high mix low volume environment is a challenge.
But imo the best way to check a mix is still listening from another room through an door open. Quality begins with good documentation for each product design. Examples of high mix low volume manufacturers would be those that have sic standard industrial classification codes such as 20xx, 23xx. Adapting lean for highmix, lowvolume manufacturing facilities. Mar 06, 2014 here are a few steps that can support quality efforts for manufacturers involved in highmix, lowvolume assemblyparticularly contract manufacturers dealing with a diversity of products for different customers. Generally i think that low levels are great for working on a mix while high levels are good for checking the mix. Jun 05, 2014 heijunka for high mix low volume environments duration. Mar 05, 2004 the strategies for highmix, lowvolume assembly are often opposite from those for highvolume, lowmix production. Mini softcover matte photo books with thick, layflat pages. Buy highmix lowvolume manufacturing hewlettpackard. There is still a stigma about low volume, high mix lean manufacturing.
Greg used tps to grow the business and nearly double its sales. Many electronic contract manufacturers are purely revenue driven, and are mainly interested in high volume customers. Pdf lean transformation in a high mix low volume electronics. Aug 15, 2007 this is a true how to book for implementing lean concepts into lowvolume highmix manufacturing. Highmix, lowvolume manufacturing covers the entire. Its also a problem thats close to my heart as a former material manager for an aerospace company. This book is specifically geared for manufacturers that have hundreds to thousands of. Buy highmix lowvolume manufacturing hewlettpackard professional books book online at best prices in india on. While a consistent process may be dull, it will also yield superior results. However, this production scheme has traditionally yielded lower quality output because of variation.
The content of the book covers a widerange of manufacturing topics. Create totally custom photo goods that reflect your. Pdf efficient material allocation in highmix lowvolume. Banks, senior vice president and operating officer, parker hannifin corporation, july, 2007. Although there is a special focus on high mix, low volume manufacturing, there is much useful and valuable information for people in all other types of manufacturing. I read an interview with a mixer in behind the glass. Adapting lean for small and medium highmix low volume manufacturers. Through implementing polca we dramatically reduced our workinprocess wip, freeing up cash and creating additional space for manufacturing. Reasons for the changes fabrinet serves an industry characterized by very high mix, low volume production. Highmix lowvolume manufacturing hewlettpackard professional. Although value stream mapping has been proven to enhance many types of processes, its advantages are shrunk if they are implemented in high mix, low volume processes. High mix, low volume unstructured bin picking and produce picking duration.
Michael mahoney, president of manufacturing decision analysis llc loveland, co. However, managing lowvolume highmix operations is different from managing highvolume lowmix operations like, for instance, consumer electronics. The author assumes the reader has some prior experience with the traditional lean concepts, so the emphasis is on how to apply those concepts to the lowvolume highmix environment without reexplaining the why or what, but rather just the how. Value stream mapping adapted to high mix, lowvolume. Operational excellence within a low volume high mix business. Efficient material allocation in highmix lowvolume manufacturing article pdf available in journal of advanced manufacturing systems 92 february 2010 with 1,409 reads how we measure reads. The market advantages of highvariation lowvolume production are clear.
High mix, low volume manufacturing covers the entire spectrum of manufacturingrelated topics, from competitive strategies through performance measurements. Heijunka for high mix low volume environments duration. How to automate lowvolume and highmix applications. Highmix, lowvolume manufacturing is a groundbreaking work, integrating ideas from many sources. High mix low volume customers frequently find their schedules are being unpredictably delayed as their ems vendor shifts committed manufacturing capacity towards high volume. Nov 14, 2016 vsm 3 vsm in highvariation, lowvolume production environment duration. Excelling in a highmix, lowvolume environment crc press book toyota production system methods have rendered remarkable results in highvolume manufacturing plants, but they have not been fully understood and correctly applied in highmix, lowvolume environments. In addition, our internal chaos decreased, and customer satisfaction and profitability increased. Excelling in a high mix, low volume environment 1 by lane, greg isbn.
A new book by former deputy undersecretary of the navy seth cropsey stirs this. However, it can be utilized in low volume and high mix production by means of an adapted leveling approach presented in this paper. Highmix lowvolume manufacturing hewlettpackard professional books r. The author assumes the reader has some prior experience with the traditional lean concepts, so the emphasis is on how to apply those concepts to the low volume high mix environment without reexplaining the why or what, but rather just the how. In his first book, highmix, lowvolume manufacturing, r. Mar 03, 2014 whereas pa is usually best utilized in a low mix high volume environment, we are attempting to use it in a high mix low volume environment, which presents a certain degree of risk. So, while it is imperative that hmlv manufacturers embrace lean as a philosophy, maybe they should not do it by following only what is best for an automobile manufacturer. Our new premium lustre lay flat photo book features thick pages with a glossy, subtle sheen that will make your photos pop with color. Great book for any manufacturer that has low volume high mix. The challenges for a low volume high mix, like the one above described. Lean manufacturing kaizen methodology lean fastcap style duration.