The Tiger Team from Hoerbiger looks for ways to cut waste and improve throughput in the company's assembly cell.

This is the first article in an eight-part "reality" series on implementing continuous improvement at Hoerbiger Corporation. Throughout 2013, Dr. Shahrukh Irani will report on his progress applying the job shop lean strategies he developed during his time at Ohio State University.

In the August issue, we examined the lean tools that will and will not work in high-mix, low-volume manufacturing facilities. Now, we will examine how to implement the tools that will work in the job shop with an approach that expands the capabilities of value stream mapping.

Why traditional lean manufacturing approaches need to be adapted for job shop environments.

Make no mistake -- lean manufacturing is here to stay. And no wonder. As a fiercely competitive global economy continues to alter companies’ “Main Street” thinking, that relatively new dynamic is spurring the need for “I-need-it-yesterday” production output. And for increasingly more industries -- big or small -- that means getting as lean as you can, as fast as you can.

Two high-volume gear production cells grace the shop floor at Delta Research Corporation in Livonia, Michigan. Thanks to lean manufacturing, these cells have never shipped a defective part to a customer since they were developed over three years ago.