1

Alain Prioul

Flexibility / Adaptability

2

Definitions

Flexibility

Ability to follow customer demandat different Takt

Time

Ability to quickly change from one part number to

another one

Adaptability

3

Flexibility

4

To reduce WIP + surface + handling + CAPEX

Key condition for high TRS

Key condition for levelling

To reduce lead time

Flexibility : Why ?

5

tt

QQ

A B C A

tt

QQ 12 h

Stock level AStock level A

Production (batch size 12h)Production (batch size 12h)

Safety stock

Average stockAverage stock

Reduce inventories

6

tt

QQ

Average stockSafety stock

tt

QQA B C A B C A B C A B C A B C A B C A B C A B C

Stock level AStock level A

Production (batch size 2h)Production (batch size 2h)

12 h

Reduce inventories

7

Safety stock tt

QQ

tt

QQA B C A B C A B C A B C A B C A B C A B C A B C

Stock level AStock level A

Production (batch size 2h)Production (batch size 2h)

12 h

Average stock

Reduce inventories

9

100%

75%

18h

1h

5h

A9h

B9h

5h

P1

C

D

5h

P2

E

F

P3

G

H

P4 P(x)

TRS Increase

10

9h

9h

5h

P1

2h

2h

5h

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

x2 x9

TRS Increase

11

5h

9h

9h

5h

P1 P2 P3 P4 P5 P6

x2

2h

2h

2h2h

2h

2h

2h

2h

2h

2h

2h

x9

TRS Increase

12

9h

9h

5h

2h

2h

P1

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

x2 x9

2h

2h

TRS Increase

13

9h

9h

5h

2h

2h

P1

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

2h

2h

x2 x9

TRS Increase

14

9h

9h

5h

2h

2h

P1

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

2h

2h

x2 x9

TRS Increase

15

9h

9h

5h

2h

2h

P1

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

2h

2h

x2 x9

TRS Increase

16

9h

9h

5h

2h

2h

P1

2h2h

2h

2h

2h

2h

2h

P2 P3 P4 P5 P6

2h

2h

x2 x9

TRS Increase

17

To reduce WIP + surface + handling + CAPEX

Key condition for high TRS

Key condition for levelling

To reduce lead time

Flexibility : Why ?

18

Ideal condition:

Producing all products in parallel at TAKT TIME

(rhythm of customer demand of each part number)

Target : respect the TAKT TIME & full loading of the equipment:

Producing all products in small batches close to TAKT TIME

Levelling

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Customer demand

Production = Large batches

Lead Time reduction

Production = small batches

Lead time

Lead time

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Adaptability :

Flexible Manpower Line

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Flexible Man Power Line : why ?

Work Content change

Customer demand

change

n => n - 1

Takt Time change

Result of Kaizen action

Work content mix

Work ContentNumber of Operators = Takt Time

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Flexible Manpower Line

A line which is designed in such a way

that productivity is the same, whatever is

the number of operators.

Flexible Man Power Line : Definition

Flexible Manpower System

Optimizing labour productivity factory-wide by

moving people from one flexible manpower line to

another.

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Flexible man power line : Layout

U cell Linear (fixe)Unflexible man power line

A

B C

D

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Flexible Manpower Line : Fundamentals

•Linear line configuration or U shape line

•No barrier to operator movement

Line

Operator•Operators work inside the cell

•Operator loaded to takt time

•Operation start and finish at the same point

•One piece product flow by hand

Process

•Standard in process stock Multi-process handling

• Several Standard Work for varying demand

• Flexible working hours

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Flexible Manpower Line : Iso-productivity !

6 operators Demand - 15 % => 5 operators

Demand - 30 % => 4 operators Demand - 50 % => 3 operators

PPH is constant

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- avoid overproduction => less WIP , space , handling

- smooth production => better usage of capacity

- smooth material flow => control lead time

- create standard conditions

- make kaizen possible

Flexible Manpower Line

Flexible Manpower Line