LEANINOVATIONMiloš Bugan
BASIC FACTS:
CEIT is a company providing comprehensive, innovative solutions for boosting productivity and efficiency of industrial enterprises.
It offers sophisticated products and services that customers and partners to ensure continued competitiveness.
Since
1998A strong team of
expertsExpert guarantor of
major conferences
Transnational
projects
TACT TIME VS CYCLE TIME ...
WHAT'S THE PROBLEM?
Waiting
Un necessary
movements
Stock
Non quality
Transport
Over production
Over processes
Not in video
REQUEST AND VALUE ...
Value added activities - directly changes the shape or characteristic of the product
/ service based on requirement's of customer
What the customer really want?
LEAN APPROACH ...
Customer requirements
Continuous flow
Pull
Perfection
Customer requirements
Continuous flow
Pull
Perfection
REQUIREMENTS, CAPACITY PLANNING? IMAPACT TO LEAN?
TimeTime
Am
ou
nt o
f
wo
rk
Am
ou
nt o
f
wo
rk
Variation
Flexibility
Strategy
A.
Strategy
B.
Who is customer?
What is expected?
What are the conditions?
Who is customer?
What is expected?
What are the conditions?
Clear answer help as on the future with ...
- Capacity
- Quality
- Timing
- Cost
Clear answer help as on the future with ...
- Capacity
- Quality
- Timing
- Cost
Max. possible
capacity
Strategy
C.
IDEAL CONTINUOUS FLOW
LT = 15 min, VA = 3 min, E= 100%
NON LEVELED FLOW
LT = 21 min, VA = 3 min, E= 68% -> LT>40%
LT = 15 min, VA = 3 min, E= 100%
BALANCING ... PREMISE FOR CONTINUOUS FLOWW
eld
Wel
d
Ass
embl
e
Ass
embl
e
Takt time60 seconds
40 s.
62 s.
46 s.
39 s.
1 s.
Stamp
Wel
d
Wel
d
Ass
embl
e
Ass
embl
e
Takt time60 seconds
40 s.
62 s.
46 s.
39 s.
1 s.
Stamp
We
ld
Ass
em
ble
Takt time = 60 seconds
We
ldA
ssem
ble
We
ld
Ass
em
ble
Takt time = 60 seconds
We
ldA
ssem
ble
TIME STANDARDS ...
5S, SW ...
An
d n
ow
...
An
d n
ow
...
PREVENTION, PROTECTION, REACTION ...
CONTINUES FLOW ...
ASSUMPTIONS, DATA, FACTS ...
KAIZEN AND INOVATION
Time
Effect
Kaizen
Innovation
FOCUS ON THE VALUE ...
Traditional option Different option
Lead time = 3 weeks Lead time = 2,5 days
INOVATION ON LOGISTICS
TOOLS ... PRACTICAL EXAMPLES - LEVEL 2
0%
10%
20%
30%
40%
50%
60%
LR HR ZEN
Chosen representatives from whole production assortment
Dotyková lišta bubna spodná
Dotyková lišta bubna vrchná
Spevňovací držiak bubna
Pružina dvierok bubna PRAVÁ
Pružina dvierok bubna ĽAVÁ
Záves dvierok bubna
Dvierka malé opracované
Puzdro zámku s poistkou
Poistka dvierok bubna
Kryt zámku bubna
Pružina dvierok ĽAVÁ
Pružina dvierok PRAVÁ
Záves dvierok bubna
Motor
Plastový kryt na motor
AC fólia motora
Odparovacia hadica
Spona na uchytenie odparovacej hadice
Plochý remeň
Remenica bubna
Magnetický zastavovač dvierok
Vzdušník
Tesnenie vzdušníka
Ohrievacie teleso
NTC snímač
Transportný kolík
Strieška na AS
Bočnica nádrže
Spona na upevnenie hadica N/Č
Tesnenie EKO gule
Hadica N/Č
Eko guľa
Tesnenie nádrže
Závažia
Spevňovací uholník
Dolné závažie (spodné)
Horné závažie zadné
Horné závažie predné
Závažie remenice
Závažie plné zo strany bočnice
Závažie zo strany motora
Závažie na agregát zo strany nádrže
Štvorcová plastová matica
Zemniaci kábel
Kovový kryt motora
Predná stena
LOGO na prednú stenu
Čerpadlo
Drôtená spona
Výtoková hadica
Držiak veka čerpadla
Veko čerpadla
Izolačná platňa
Zadná stena
Držiak s kotvou
MCU box
Držiak hadice
Príchytka vodičov
Poistka tlmiča
Tlmič
Zadné nohy
DFA analysis
Evaluation of 126 components of representative in DFA analysis.
1
3
9
Critical - minimum
Satisfying - maximum
Achievable points for
each criteria
Potential for improvement
Number of criteria
evaluated while
analyzing each
component: 8
Work analysis
2.1.
3. 4. Line balancing
New non-balanced
assembly procedure
based on outputs of
DFA
Balancing of
new assembly
procedureCreating of new assembly procedure
based on outputs from DFA
SIMULATION AND VISUALISATION
SIMULATION AND VISUALISATION
WHAT HAVE TO BE ...
LEAN PROJECTS ...
1. Lean is not about one
project – its a long way ...
2. Appoint a real leader with
competence
3. Start with small micro
project with high benefits
4. Prepare very good
„marketing“
5. Involve maximum
employee as you can
6. Don't forget – 30% is
about activities, but 70% is
about maintaining
7. Follow PDCA
THANK YOU FOR YOUR ATTENTION:
CEIT, a. s.
Univerzitná 8661/6A | 010 08 Žilina | Slovenská republika
Tel.: +421 41 513 7401 | E-mail: [email protected]
www.ceitgroup.eu