Foreword Implementation of Lean Manufacturing in Custom Forge Shops Introduction A custom forge shop, especially one that makes short production runs to supply spares to defense agencies such as the Defense Logistics Agency (DLA) and Department of Defense (DOD), must manage a complex and dynamic network of multi-product flows in their manufacturing facility. This task is made especially more difficult because of the following characteristics of a typical custom forge shop: process-oriented layout of the facility, batch-oriented and setup-intensive processes, and large equipment with deep foundations that cannot be relocated (“monuments”). These constraints severely limit the efforts of any custom forge shop in its efforts to be cost-effective and on-time, especially for short production runs. Therefore, like any other jobshop-type manufacturing facility, a custom forge shop also needs to recognize how their current facility layout helps/inhibits waste-free flows of products, people, materials, etc. In turn, this would help them to identify and prioritize the implementation of best practices and tools for reduction of operating costs and lead times using analysis tools that are suited for jobshops, and not high-volume assembly line-type facilities. With an effective layout, material handling system and shopfloor communication system in place, any forge shop could realize savings from reduced work-in-process inventory, reduced scrap and ...