
The custom manufacturing industry, including machine and fabrication shops, is no stranger to fluctuating demands and challenges with efficiency. Operating in this complex environment requires strategies that go beyond traditional production methods, which is why lean manufacturing has become a game changer.
Lean manufacturing principles—centered around reducing waste, improving efficiency, and maximizing value—are transforming job shops into thriving, streamlined environments.
This blog explores how job shops can adapt lean manufacturing practices to stay competitive. From segmenting product mixes to optimizing shop layouts, we’ll break down the key strategies for building a lean and efficient workflow.
What Is Lean Manufacturing?
At its core, lean manufacturing focuses on creating more value for customers with fewer resources. Originally popularized by Toyota, the lean approach emphasizes eliminating activities that don’t add value to the production process.
For custom manufacturers, implementing lean methods doesn’t mean sacrificing their flexibility. Instead, it’s about identifying inefficiencies unique to their operations and engineering a smarter, more purposeful system.
Why Lean Manufacturing Matters for Job Shops
Custom job shops are centered around producing specialized, often unique products in small quantities. While these shops thrive on their ability to switch between projects, this flexibility can come at a cost—reduced efficiency and increased waste.
Lean manufacturing enables job shops to mitigate these common issues by focusing on four key principles:
- Reducing waste in processes, resources, and time.
- Improving flow to ensure seamless movement of parts and tools.
- Enhancing productivity through better organization and scheduling.
- Adding maximum value to the customer while cutting down on non-essential efforts.
The Benefits for Job Shops
By adopting lean practices, job shops can achieve measurable improvements in:
- Production efficiency: Faster turnaround times without compromising quality.
- Cost-effectiveness: Reduced material waste and optimized labor use.
- Customer satisfaction: Predictable lead times and consistent product quality.
- Workforce engagement: Improved workflows lead to happier, more productive teams.
Now that you understand the importance of lean manufacturing, here’s a breakdown of actionable steps you can take to integrate these principles into your operations.
Four Key Lean Strategies for Job Shops
1. Segmenting Product Mix into Runners, Repeaters, and Strangers
One-size-fits-all production processes are rarely efficient. A key step in implementing lean manufacturing is segmenting your product mix into three categories:
- Runners: High-volume items regularly produced with minimal variation.
- Repeaters: Medium-volume items produced repeatedly but with some variation.
- Strangers: Low-volume, highly customized items with no regular production pattern.
By identifying these categories, you can focus on streamlining production for runners and repeaters while finding faster turnaround methods for strangers. For instance:
- Dedicate specific resources or machinery to high-priority runners and repeaters.
- Implement simplified setups for stranger products to save time.
- Use historical data to schedule runners and repeaters in advance while leaving buffer room for unexpected stranger projects.
2. Reorganizing Shop Layout for Better Flow
Many job shops operate with layouts designed for maximum flexibility. However, this can create inefficiencies, with parts and workers traveling longer distances than necessary.
Lean manufacturing prioritizes optimizing the physical flow of materials and tools to minimize unnecessary movement and idle time. Consider these adjustments:
- Cellular layouts: Group machines and workstations based on the specific tasks required to produce similar products, reducing the need for excess movement.
- Point-of-use storage: Place tools and materials close to where they’ll be used, saving time spent retrieving them.
- Workplace organization: Adopt the 5S system—Sort, Set in order, Shine, Standardize, Sustain—to keep your shop clean, organized, and efficient.
By redesigning your shop layout, you ensure that materials and resources move smoothly without bottlenecks.
3. Focusing on Multifunction Machines and Combined Operations
One of the cornerstones of lean manufacturing is getting the most out of your existing resources. For job shops, this means investing in multifunction machines that allow for various operations to be completed in a single setup.
For example:
- Multifunction lathes and mills can handle multiple processes like cutting, drilling, and shaping, reducing the need for frequent machine changes.
- Combined operations involve consolidating multiple steps into one, such as combining parts assembly with packaging.
The result? Faster production cycles, fewer setups, and reduced downtime between processes.
4. Implementing Dynamic Scheduling Systems
Traditional static scheduling methods often fall short in the volatile environment of job shops. A lean approach recognizes the importance of flexibility, and dynamic scheduling is the answer.
Dynamic scheduling systems adapt to real-time changes in demand, such as last-minute order modifications or machine breakdowns. Here’s how to implement an effective scheduling system:
- Use software solutions like an ERP (Enterprise Resource Planning) system to monitor real-time shop floor data.
- Build buffer times into your schedule to accommodate unexpected delays without impacting other projects.
- Prioritize tasks based on value and deadlines to ensure the highest-priority jobs are completed first.
By responding dynamically to the needs of your shop, you’ll accomplish more while maintaining predictable timelines.
Small Changes, Big Impact
Lean manufacturing isn’t about reinventing the wheel; it’s about smoothening the ride. By implementing these principles, job shops can achieve better efficiency, reduced waste, and the ability to offer more value to their customers.
If you’re just getting started, don’t feel the need to make every change all at once. Instead:
- Begin with small, impactful changes, such as reorganizing your layout or investing in multifunction machines.
- Test and refine processes to ensure you’re moving in the right direction.
- Keep evaluating your workflows to identify and eliminate inefficiencies over time.
Lean manufacturing is an ongoing process, but even incremental efforts can drive powerful results.