5.1 workflow

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Workflow

Continuous Flow

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The Traditional Approach

Delay | Transport | Storage

Long distances

Long lead timesOperation 2

Operation 3

Operation 1

High WIP

Hi h cost

Poor problemsolving & teams irit

Operation 5

Operation 6 Operation 7

2

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Dedicated Line Solution

Operation 3

the delaysOperation 4

Operation 2

Operation 5

Operation 1

and storage timesOperation 6 Operation 7

Operation 6 Operation 1 Operation 6 Operation 5 Operation 7Operation 2

Operation 1 Operation 2 Operation 7

thanks to parts families and dedicated lines

Operation 4Operation 6

Operation 1

Operation 1 Operation 5 Operation 2 Operation 5 Operation 7

rather than diffused lines

Operation 4

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Steps to implement dedicated lines

Define PARTS FAMILIES

Design IDEAL DEDICATED LINES

Find solutions to ACTUAL CONSTRAINTS

Find solutions to ORPHAN PARTS

Find solutions to MEET THE DEMAND

Implement dedicated lines and

ONE-PIECE FLOW Operation 6 Operation 1 Operation 6 Operation 5 Operation 7

Operation 1 Operation 2 Operation 7Operation 4 Operation 6Operation 1

Operation 2

Operation 1 Operation 5 Operation 2 Operation 5 Operation 7Operation 4

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Define parts families based on

High volume (80/20)

g va ue

Similar by e orm

the material

Runners, repeaters and strangers

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Create Process Families

Parts

A X X X X

B

C

X

X

X

X

X

X

X

XIdentify thearts and their

D

E

X

X

X

X

X

X

X

X

X

X

X

X

process

F

G

X X

X

X

X X

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Parts

A X X X X

similarBC

X

X

X

X

X

X

X

X

D

E

X

X

X

X

X

X

X

X

X

X

X

X

F

G

X X

X

X

X X

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Parts

A X X X X

family byD X X X X X XE X X X X X X

B X X X X

G X X X

C X X X X

F X X X

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Analyse the Processes

Machine

Plant: Team: Date:PARTS/PROCESS MATRIX

Cutter Auto Single Multi MultiMilling Wash Rollin

Milling Broach

Process

No lathe purposelathe

spin edrill

sp n etapping

mac ne tank

machine

hub mac ne a e

Cutting Lathecutting

Lathe cut2

Drilling Cham-fering

Screwcuttin

Milling Clean-ing

Rolling Gearteeth

cutting

Milling DrillingDebur-ing

1

2

Part #Qty

9985M26

9176M25

3

4

9383M42

9522M60

5

6

9522M58

9522M50

8

9

10

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Align the processes to optimise families

1 2 3 4 5tA

Op 1 Op 2 Op 3 Op 4 Op 5 Op 6

6 7 8Pa

COMBINE 4 5 6 7PartB

1 2 3

654PartC

1 2 3 4 5 6arts

B

&

C

A,

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Find solutions toACTUAL CONSTRAINTS




ONE-PIECE FLOW

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Design ideal dedicated lines

One line per parts family

e s ortest pat rom raw mater a s to n s e part nc u ng

every operation

ever function

support activities

specialised activities

The total linkage of all operations and functions required to make apart (everything is linked by an imaginary conveyor)

U shaped flow lineOp 4

Op 6

Op 2

Op 1 Op 7

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Find actual constraints

Op 4

O 3

Op 6Op 2

p p

Op 1 Op 7

External operation

Shared operation

Immoveable plant/equip

Limited skills

Close proximity

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Find solutions to actual constraints

Op 5

K Op 5

Op 4

Op 3

Op 6

Op 3

Op 2

Op 1 Op 7

Op 6Op 2

Op 1 Op 7 Op 4 Op 4

Op 4

Op 4

Op 5

Op 6

p

Op 2

Op 1 Op 7

External operation

Shared operation

Move cell to plant/equip

,

Retrain or move the skills

Move together proximity

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Find solutions to orphan parts

Can a dedicated line adopt them ?

ou a o s op ne e create

Can we use moveable equipment and flexible lines ? Should they be outsourced ?

Etc.

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Design realistic dedicated lines

Fishbone

Line

U Line

L Line

Back to Back

I Line

Lines

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Find solutions to ACTUAL CONSTRAINTS




ONE-PIECE FLOW

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Batch vs 1 Piece Flow

Batches and delays

One-piece flow

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Batch vs Flow (Push vs Pull)

5 parts

ow oow oA B C D

par= 10 h = 10 h = 10 h = 10 h

First

good

part

storage, transport andstorage, transport and0.0 10.0 20.0 30.0 32.0

Batch processing builds large stocks

1 part2 h/ part

First good part

PiecePieceA B C D

Second

good part

FlowFlow0.0 2.0 4.0 6.0 .One piece flow eliminates delays and waiting time

2.0 4.0 6.0 8.0 .

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The Customer Heartbeat Takt Time

Time per day

Parts per day

Data 420 production minutes per day(8 hours = 480 min - 60 Minute Break)

6 parts per day(120 parts per month - 20 Production Days

= =TAKT

Solution

420 mins /day 70 min/part y

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Example Production Line

Required quantity = 6 per day (420 min/day)

TAKT time = 70 minutesCycle time operation 1 = 70 minutes

=

Cycle time operation 3 = 50 minutes



Op 4Op 5Part

completed

Process time ofeach o eration

Op 3

Raw

materialOp 1 Op 2

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Line Balancing

TAKT: 70 MINUTESO 4O 5Part

Process capacity of the line

Op 3

= par every m nu esRaw

materialOp 1 Op 2

???

Op 1

Op 2

Op 3Op 4

Op 5 = set-up time

CYCLE TIME DIAGRAM = production time

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Line Balancing

O 4O 5Part

TAKT: 70 MINUTES

Op 3


Rawmaterial

Op 1 Op 2

???

= par every m nu es

Op 1

Op 2

Op 3Op 4

Op 5 = set-up time


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Line Balancing

O 4O 5Part

TAKT: 70 MINUTES

Op 3


Rawmaterial

Op 1 Op 2

OK

= par every m nu es

Op 1

Op 2

Op 3Op 4

Op 5 = set-up time


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Summary

ELIMINATE

the delaysOperation 4

Operation 2

Operation 3

Operation 1

the transport

and storage times

Operation 6 Operation 1 Operation 6 Operation 5 Operation 7

thanks to parts families and dedicated lines

Operation 2

Operation 5

Operation 6 Operation 7

. -

2. Implement 1 piece flowOperation 1 Operation 2 Operation 7Operation 1 Operation 5 Operation 2 Operation 5 Operation 7

rather than diffused lines

Operation 4

Operation 4 Operation 6Operation 1

Batches and delaysBatches and delays3. Balance the line to the

Takt time

One-piece flowOne-piece flow Op 4Op 5Partcompleted Op 4Op 5PartcompletedTAKT: 70 MINUTES

= 1 part every 70 minutes

Rawmaterial

Op 1 Op 2

Op 3

Rawmaterial

Op 1 Op 2

Op 3

0 20 40 60 80 100 1200 20 40 60 80 100 120OK


= 1 part every 90 minutes

Op 2

Op 3

Op 4

Op 5 = set-up timei i

= set-up time

i iCYCLE TIME DIAGRAM = pro ucion ime= pro ucion ime

5.1 workflow

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