460-operations-4-6-110525112121-phpapp02

7/25/2019 460-operations-4-6-110525112121-phpapp02

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History of Manufacturing

1875 195019251900

Made to customer specifications

20001975 2025

Craft Production

Lean Production

Mass Production

Variable quality

in!le piece manfuacturin!

"nterc#an!eable parts $ %li itney

'i!# cost(((made for t#e )ealt#y

Minimal in*entory

'i!# product *ariety

+ssembly lines $ 'enry ,ord

Lo) product *ariety $ 'enry ,ord

-i*ision of labor $ ,rederic. /aylor

Labor strife

educed lead times

Parts Per Million PPM quality

mall batc# si3es

%n!a!ed )or.force

Pascal -ennis4 pp( 1$11

Dysfunction &or.

+lienation

uality

Mac#inery

%n!ineerin!


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What is Value?Value

+ capability pro*ided to a customer at t#e ri!#t

time at an appropriate price4 as defined in eac#

case by t#e customer

pecify *alue from t#e perspecti*e of t#e finalcustomer or end user

+s. #o) your current products and processes

disappoint your customer6s *alue epectations


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4/91

Value System /#e *alue c#ain of suppliers )#o pro*ide inputs ra) materials4 components4and purc#ased ser*ices to t#e firm6s *alue c#ain t#at passes its products t#rou!#

its distribution *alue c#ains to a purc#ased input to t#e *alue c#ain of t#e buyer

upplier

Value C#ains

,irm Value

C#ain

-istribution

Value C#ains

:uyer Value

C#ains

Manufacturin!uppliers -istribution :uyer

,lo) of ;oods and er*ices

8?

Manufacturin!

and upply

C#ain trate!y

0?

-esi!nin!


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Value Stream Definition

%ntire set of activities bot# *alue added and non$*alue addedrequired to

desi!n4 order4 andma.e from ra) material to t#e finis#ed !ood a specific

product4 product family4 or ser*ice t#at see.s to eliminate )aste and

optimi3e t#e producti*e system in order to satisfy t#e final customer

"ncludes all t#e acti*ities needed to proceed from Concept to launc# -esi!n


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Definitions of !ean Process for doin! more )it# less and less B less

#uman effort4 less equipment4 less time4 and less

space B )#ile comin! closer and closer to pro*idin!

customers eactly )#at t#ey )ant

ames &omac. and -aniel /( ones

+ systematic approac# to identifyin! andeliminatin! )aste t#rou!# continuous impro*ement

by flo)in! t#e product at t#e pull rate of t#e

customer in pursuit of perfection

Process of analy3in! information and material flo)sin manufacturin! en*ironments and continuously

impro*in! t#e process to ac#ie*e en#anced *alue for

t#e customer


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!ean "hin#ing Cost reduction principle $"oyota%

Price ,ied B Cost D Profit

educe internal costs to ensure profit

&undamental o'(ectives Concentrate on eac# product4 ser*ice4 and

its *alue stream rat#er t#an or!ani3ations4

assets4 tec#nolo!ies4 and career pat#s

+s. )#ic# acti*ities are )aste and )#ic#

acti*ities truly create *alue

%n#ance t#e *alue and eliminate t#e )aste

muda to optimi3e t#e )#ole *alue streamE

!ean Core )oals PC-M


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House of !ean


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A+ "hin#ing for Hard "imes
http://echo4.bluehornet.com/ct/3970636:4640283107:m:1:78888833:DD34C164148000E048BBE436A3B34541http://echo4.bluehornet.com/ct/3970636:4640283107:m:1:78888833:DD34C164148000E048BBE436A3B34541


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!ean ,nterprise rinciples pecify valuein t#e eyes of t#e

customer

"dentify and map t#e value

stream

%liminate t#e 8 deadly -astes Ma.e *alue and )or.flo-

ull)or. at t#e rate of customer

demand

"n*ol*e and empo-eremployees Continuously improve.ai3en in

t#e pursuit of perfection


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!ean Culture

.rgani/ational Culture /#e specific collection of assumptions4 beliefs4 *alues4 and normal be#a*ior t#at are s#ared by people and

!roups in an or!ani3ation and t#at control t#e )ay t#ey interact )it# eac# ot#er and )it# sta.e#olders

outside t#e or!ani3ation

!ean Culture Plan$-o$C#ec.$+ct P-C+

tandardi3ation

tandard &or. and Problem ol*in! 5 ys

Visual Mana!ement

54 ;ood #ouse.eepin!4 Visual Controls

/eam)or.

afety4 ecurity4 Fo %ecuti*e Pri*ile!es4 ;enc#i ;enbutsu G;o eeH

Parado

ido.a4 C#an!in! tandards4 in!le Piece ,lo)4 /a.t /ime4 Perfection

"ntensity

"dentify Muda &aste4 Iai3en continuous impro*ement

Lean as a Pat#

'umility4 Lifelon! Learnin!4 espect for People


15/91

"eam resentations ro(ect0 Value Stream Mapping

ProJect Pro!ress eport

5 minutes for Presentation

tructure of ,inal ProJect Presentation

15 Minutes for Presentation

10 Minutes for Presentation

5 Minutes for uestions

Maimum 10 Po)erPoint lides

"ncludin! "ntroductory and

Conclusions lides +ll team members must participate

"n*ite Company Contact Person to

+ttend

Peer %*aluations

-esi!nin! and"mpro*in!


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17/91

ro(ect "eam Meetings

Value tream Mappin! ProJect Current tate Value tream Map and

ma.e recommendations

ee Course


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19/91

,ight Ma(or Wastes -

+cronym? - < & F / " M %

Overproduction

efects


20/91

Categories of Activities Value Added $VA% 2 Actual Wor#

teps in t#e *alue stream t#at increase

t#e )ort# of a product or ser*ice for

)#ic# t#e customer is )illin! to pay

+s. questions

"s t#is somet#in! t#e customer )ould be

)illin! to pay for

'as it p#ysically impro*ed t#e form4 fit4

or function of t#e product or ser*ice

&as it done ri!#t t#e first time


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Definition of Waste Waste $Muda%

+nyt#in! ot#er t#an t#e minimum amount of

equipment4 materials4 parts4 space4 and

)or.ers6 time )#ic# are absolutely essential

to add *alue to t#e product or ser*ice

+ny acti*ity t#at consumes resources but

creates no *alue to t#e product or ser*ice

&aste only adds cost and time4 not *alue

&actors to 3emem'er a'out Waste

&aste is really a symptom rat#er t#an a rootcause of t#e problem

&aste points to problems )it#in t#e system

at bot# process and *alue stream le*els

ou need to find and address causes of )aste


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Categories of Waste "ype I Waste $Muda% 2 Au1iliary Wor#

+dds no *alue but is necessary

/oyota Motor Corporation of apan calls

t#is GFon$Value +dded &or.H FV+

/rainin!4 facilities4 inspection4 payroll

"ype II Waste $Muda% +dds no *alue and a*oidable

&al.in!4 re)or.4 searc#in! for tools4transportation4 setups4 meetin!s

Most of engineering and manufacturingefforts fall under -hich category?


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Distri'ution

of Activities

&aste

Fon$Valued

+dded &or.

Value

+ddin!

&or.

%amples?

&eld flan!e onto part

:olt part onto product

%amples?

&al.in! to !et parts

&aitin! time

%amples? Pull do)n tool

@nclamp N clamp fiture

Cate!ories of &or. +cti*ities

+cti*ities


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House of !ean*,ight Wastes

%i!#t

&astes

uality at t#eource /M

5 ystem

Visual Controls

-esi!n for

Manufacturin!

Iai3en

/eams

Point of @se

tora!e

/a.t

/ime

;roup

/ec#nolo!y

uic.

etup M%-

tandardi3ed

&or.

PlantLayout

:atc# i3e

eductions

Cellular

Manufacturin!

Value tream Mappin! VM

in!le$Piece

,lo)

/otal Producti*e

Maintenance /PM

Pull K Ianban

ystem "/

Lean %nterprise


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Video0 4Mercury Marine5 .vervie- of Manufacturing rocess

122 indi*idual steps to ma.e a -ri*es#aft 'ousin!

27 production steps B about 20O of t#e total number

/ra*el distance D 20479 feet about = miles

14=9> #ours in process about 19 )ee.s 10> people touc#ed assembly or paper)or.

Discussion 6uestions "dentify and pro*ide eamples of = types of process -aste depicted

in t#e *ideo

"dentify potential acti*ities t#at could be conducted in parallel

and increase t#e capacity of t#e current process

'o) can Mercury Marine utili3e .ai3en e*ents to impro*e t#eir

supply c#ain process
http://www.mercurymarine.com/


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Overproduction

.verproduction Waste


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.verproduction

/rue %fficiency B 8 operators 100 pieces

+pparent %fficiency B 10 operators 120 pieces

Current tate B 10 operators 100 pieces

Customer

G:ut " only need

100 piecesH


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Inventory Waste


29/91

Ape1 Cell !ayout /oo muc# )al.in! distance +mple space for accumulatin! &"P "nside of cell too )ide /ube bender needs modification

Lead$off and final operations too far apart


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Waste in 78S8 Manufacturing

Waste in Manufacturing &acilities is 7suallyDisguised as0

Lost /ime

"nJury +ccident crap

e)or.

%quipment etups

%quipment -o)ntime

"nspection

"n*entory tora!e Countin! "n*entory

upplier Lead /imes

Product /est


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Commentary on Waste

G


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Muri9 Mura9 Muda Muri

train4 difficulty4 #ard to do


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House of !ean*:ai/en

%i!#t

&astes

uality at t#eource /M

5 ystem

Visual Controls

-esi!n for

Manufacturin!

Iai3en

/eams

Point of @se

tora!e

/a.t

/ime

;roup

/ec#nolo!y

uic.

etup M%-

tandardi3ed

&or.

PlantLayout

:atc# i3e

eductions

Cellular

Manufacturin!

Value tream Mappin! VM

in!le$Piece

,lo)

/otal Producti*e

Maintenance /PM

Pull K Ianban

ystem "/

Lean %nterprise


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35/91

DVD0 4"oast :ai/en5


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DVD0 4"oast :ai/en5 &aste

&aste is identified t#rou!# direct obser*ation

/aic#i


37/91

What is Wor#? Definition of Wor#

'uman motions in*ol*ed in producin! products

/#ese actions can be di*ided into t#ree cate!ories

Value$added or creatin!

Mo*ements directly necessary for ma.in! products4 suc# asassemblin!4 )eldin!4 drillin!4 and paintin!

"ncidental or Fon$*alued added )or.

Motions t#at operators must perform to ma.e products but

)#ic# do not create *alue from t#e standpoint of t#e customer

&aste

Motions t#at create no *alue and )#ic# can be eliminated

Wor# element mallest increment of )or. t#at could be mo*ed to anot#er person


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,1ercise ;0 Ape1 Manufacturing

Ape1 Welding rocess Process flo) dia!ram

/able of )or. elements and )or.

element times for )elded part

Assignment e*ie) t#e process flo) dia!ram

e*ie) t#e 1= )or. element steps

@nder t#e Motion Cate!ory4

cate!ori3e eac# )or. element as only

one of t#e follo)in!?

& D &aste

" D "ncidental non$*alued

added &or.

V D Value$+dded &or.

1= &or. %lements D 50 econds


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,1ercise ;0 Ape1 Wor#

Classification


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Standard Wor# Definition

Lean tec#niques in continuous flo) production to assure maimum

performance t#rou!# .ai3en by minimi3in! )aste t#rou!# t#e best

combination of operator and mac#ine

.'(ective %stablis# precise procedures for eac# operator6s )or. in a

production process based upon?

/a.t /ime B rate at )#ic# products must be made in a process to

meet customer demand

&or. equence B order in )#ic# an operator performs tas.)it#in ta.t time in a !i*en process

tandard &or. "n$Process &"P "n*entory B units4 includin!

t#ose in mac#ines4 required to .eep t#e process operatin!

smoot#ly )it#out t#e operator standin! in front of a mac#ine


42/91

Standard Wor# Benefits

rocess Sta'ility atisfy producti*ity4 quality4 cost4 deli*ery4 safety4 and morale

Clear Start and Stop oints for ,ach rocess

.rgani/ational !earning

etains operator and process .no)led!e

Assess Current Condition and Identify ro'lems "s t#e process smoot# or are )or.ers failin! be#ind and )#y

,mployee Involvement and o#ayo#e $mista#e proofing%

:ai/en tandard &or. pro*ides stable process for impro*ement

"raining :asis for employee trainin!


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Standard Wor# Definitions

"a#t "ime +*ailable production time di*ided by customer demand

%stablis#es t#e rate or r#yt#m for tandard &or.

+*ailable Production /ime

/a.t /ime D

Customer -emand

Cycle "ime


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Standard Wor# Definitions

"otal roduct Cycle "ime or roduction !ead "ime /#e time it ta.es one unit or piece to mo*e all t#e )ay t#rou!# a

process or *alue stream

+t t#e plant le*el4 t#is is termed door*to*door

"otal .perators 3e


45/91

erspectives on Standard Wor#

Benefits -ocumentation of t#e Current tate process for all s#ifts

eductions in *ariability

%asier trainin! of ne) operators

eductions in inJuries and strain

:aseline for .ai3en acti*ities

%poses problems and facilitates problem$sol*in!

'elps standardi3e effort

rere


46/91

Standard Wor# Diagrams

Basic documentation for Standard Wor# tandard &or. C#art

c#ematic of t#e p#ysical layout of a cell or process

/ime


47/91


48/91

"ime Wor# ,lements Collect real time at processes t#ru direct obser*ation


49/91

"ime .'servation*Current State

Map


50/91

,1ercise0 "ime .'servation Studies

.'(ective %ducate students on t#e basic process of time studies by demonstratin! )or.sequence4 )or. elements4 tandard &or.$in$Process &"P in*entory4

quality c#ec.s4 and obser*ation points for data collection

Manufacturing Scenario

Materials Mac#ine Posters

upply of H 5H Post$"n Fotes4 Mas.in! /ape4 Mar.in! Pen

top)atc#es4 Calculators4 and /ime


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52/91

,1ercise0 Standard Wor# Sheet;


53/91

,1ercise0 &irst Simulation 3un "nstructor


54/91

"ime .'servation &orm

Measure Manual and Wal#ing "ime for a rocess /otal


55/91

"ime .'servation &orm ,1ample

Problems and %ercises


56/91



57/91

&irst Simulation 3un erform simulation

in!le


58/91

,1ercise0 Standard Wor# Sheet >


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,1ercise0 Second Simulation 3un Perform total process after t#e "nstructor says /+/

Pic. up Post$"t from a) Materials Location

@nload Processed Post$"t from Mac#ine 1

Load Fe) Part on Mac#ine 1 and Press tart :utton((/"M%

Mac#ine 1 Cycle /ime10 seconds

&al. to Mac#ine 2 )it# Processed Part from Mac#ine 1 /"M%

@nload Processed Part from Mac#ine 2

Load Processed Part from Mac#ine 1 and Press tart :utton /"M%

Mac#ine 2 Cycle /ime 8 seconds

Perform uality C#ec. on Processed Part emo*ed from Mac#ine 2(((/"M%

&al. to Mac#ine )it# ProcessedK+ppro*ed Part from Mac#ine 2(( /"M% @nload Part from Mac#ine and Load Processed Part from Mac#ine 2

Press tart :utton and Place Part in ,inis#ed ;oods Location(( /"M%

Mac#ine Cycle /ime12 seconds

&al. bac. to a) Material tora!e Location(( /"M%


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Second Simulation 3un erform simulation


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Standard Wor# Com'ination Sheet &illing out a Standard Wor# Com'ination Sheet

"ndicate t#e sequence of steps in t#e operation and description of operations

Manual times dra)n from t#e /ime


63/91


64/91

.perator Balance Chart .'(ectives

"dentify )#ere operators are under$utili3ed and )#ere t#eir process

cycle time is !reater t#an t#e ta.t time

Leads to more detailed analysis of t#e process usin! t#e tandard &or.

Combination #eet

Constructing an .perator Balance Chart @se t#e data best time from t#e /ime


65/91

.perator Balance Chart


66/91

,1ercise0 Standard Wor# Sheet +


67/91

,1ercise >0 Ape1 Manufacturing

Ape1 Welding rocess /able of )or. elements and )or.


Assignment Calculate t#e /a.t /ime

+*ailable /ime per #ift

Construct t#e


68/91

,1ercise ;0 Ape1 &lo-

Diagram



69/91


Classification


70/91

S d d : i


71/91

rocess Study and :ai/en

rocess Study &orm :est )ay to do t#e Job

epeatedly obser*ed actual )or.

aper :ai/en +pproac# of immediately lea*in! out )aste

-o not include any )al.in!as a )or. element

-o not include !ettin!ra) material or placin!parts on tables

-o not include out$of$cycle )or.for operators as )or. elements

Periodic )or. li.e feedin! a mac#ine e*ery 25 pieces

;ettin! a bin of parts or ma.in! a quality c#ec. -o not include operators )aitin!for mac#ines to cycle

-o not include time for remo*in!finis#ed parts from mac#ines

)#en you belie*e t#at automatic eJect could be introduced

aper :ai/en


72/91

aper :ai/en 2

.perator Activity Chart

-etail t#e specific )or.elements of eac# )or.er

-isplays cumulati*e time toperform one product cycle

#o)s t#e interaction

bet)een


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,1ercise +0 Ape1 Manufacturing

Ape1 Welding rocess /able of )or. elements and )or.


Assignment Paper Iai3en

at steps )ould you

eliminate in t#e process

Construct t#e


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Classification

A 'l !i B l i


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Assem'ly !ine Balancing

Steps in Assem'ly !ine Balancing $A!B% Construct Precedence -ia!ram

%stimate /as. /imes

/ime


76/91

!ine Balancing rocedure

-etermine t#e tas.s )or. elementsrequired to complete one finis#ed unit

and t#e sequence in )#ic# t#e tas.s

must be performed

Construct an assembly precedencedia!ram

%stimate tas. times +mount of time it ta.es a )or.er usin!

standard times to perform eac# tas. -etermine t#e ta.t or cycle time

+mount of time bet)een successi*e units

comin! off t#e line


77/91


78/91

A 'l !i Di


79/91

Assem'ly !ine Diagram

A 'l !i B l i


80/91


roduct !ayout * Assem'ly !ine Pro!ressi*e assembly lin.ed by some material #andlin! de*ice

Assem'ly !ine Balancing Algorithm

1( -e*elop precedence dia!ram4 current cycle times4 )or. elements

2( -etermine t#e Cycle /ime C/?

C/ D +*ailable &or. /ime K equired output per day in units

( -etermine /#eoretical minimum number of )or. stations Ft

FtD um of tas. times / K Cycle /ime C/

=( elect +ssi!nment 'euristics

5( +ssi!n tas.s until sum of tas. times equals cycle time

>( %*aluate t#e efficiency of t#e assi!nment solution

%fficiency D um of tas. times K R Fa S Cycle /ime C/ T

7( "f efficiency is unsatisfactory4 apply different assi!nment #euristics

A i t H i ti


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Assignment Heuristics !argest um'er of &ollo-ers

+ssi!n tas.s to )or. stations by selectin! t#e feasible tas. t#at

#as t#e lar!est number of tas.s follo)in! it bac. t#rou!# t#e

sequence of assembly

!ongest .peration "ime +ssi!n tas.s to )or. stations by selectin! t#e feasible tas. t#at

#as t#e lon!est operation time

!argest 3an#ed ositional Weight an.ed positional )ei!#t is t#e sum of a specific tas.6s operation

time and t#e times of all t#e tas.s t#at follo) it bac. t#rou!# t#esequence of assembly

+ssi!n tas.s to )or. stations by selectin! t#e feasible tas. t#at

#as t#e lar!est ran.ed positional )ei!#t(

A 'l !i B l i


82/91


Steps in Assem'ly !ine Balancing $A!B% Construct Precedence -ia!ram

%stimate /as. /imes

/ime


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Assem'ly !ine Wor# Stations

Precedence Fet)or. for +ssembly

+

=5 sec(

15 sec(

12 sec(

12 sec(

12 sec(

8 sec( 9 sec(

12 sec(

50 sec(

9 sec(11 sec(

C

;

,

:

-

"

I'%

1

=

52

Assem'ly


84/91

!ine *

!."

3 # d iti l W i ht


85/91

3an#ed ositional Weights


86/91

Assem'ly Solution * 3W

Assem'ly !ine


87/91

y

,1ercise ; %ercise eadin!

+ssembly Line :alancin! %ercise 1

eliance Motor Corporation MC

Production data +*ailable )or. time D 274>00 seconds

0 motors

e*ie) t#e table )it# t#e assembly linetas.s4 duration4 immediate predecessors

Complete t#e follo)in! assi!nment? Construct t#e precedence dia!ram

at is t#e cycle time and t#eoretical

minimum number of )or. stations

+pply 1 Lon!est


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Assem'ly ,1ercise ; et-or#

Assem'ly !ine


89/91

y

,1ercise > %ercise eadin!

+ssembly Line :alancin! %ercise 2

Vancou*er acer Corporation

Production data +*ailable )or. time D 274000 seconds


90/91

Improve Cycle "ime "he longest tas# time is the shortest or

minimum cycle time

.ptions for reducing the cycle or ta#t time'elo- the longest tas# time duration

plit t#e tas. #are t#e tas.

@se parallel )or.stations

@se a more #i!#ly s.illed )or.er

&or. o*ertime

edesi!n t#e product to reduce tas. time

edesi!n t#e assembly process or )or.place

to reduce tas. time

Superior &acility !ayouts


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Superior &acility !ayouts

Manufacturing .perations trai!#t$line flo) pattern :ac.trac.in! minimi3ed

Production setup and run

times are predictable

Minimum )or.$in$processin*entory

Visible and open floor plans

:ottlenec. operations

controlled

&or.stations located close toeac# ot#er

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