Until now, many experts thought the application of Lean manufacturing in complex and variable environments was impossible in most cases. Level scheduling and standard processes, two hallmarks of Lean manufacturing, are difficult to achieve in industries that produce complex products that must be customized for specific applications. The widely varying processing times that result from the fabrication of different combinations of sub assemblies required for products in such categories make the maintenance of continuous flow, another hallmark of Lean manufacturing, seem an insurmountable goal. But the authors of this book, international consultants to companies turning out such products, have found ways to deal with these challenges and to employ Lean manufacturing techniques in order to maximize labor, plant and equipment productivity. A key aspect of the methodology explained is the use of sophisticated scheduling software to eliminate bottlenecks and to minimize downtime in the...

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