activity of product qs- lean manufacturing

8/10/2019 Activity of Product QS- Lean Manufacturing

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Activity Of The Product


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Activity of the product focuses the Product or Thing

from start to finish. - Start may mean raw materials, arrival at the dock, release of a job tothe factory floor, receipt of a request for a proposal or engineeringchange.

- Finish may mean delivery to the customer, shipment from our dock,or completion of the work by the process.

Understand what the product is doing along the way. View the process from the perspective of the Product

or Thing going through the process. Determine the actual work required to complete

processing. Determine how long it takes to do the work. Look for opportunities to improve.


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What are the Four Things the PRODUCT can be doing?

Total Thru-put

Time

50 - 80% of the Gain

Storage

Transport

Inspect

Process

Whic h Elem ent A dd s Value?

Activity of the Product or Thing

T.I.P.S.


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From The Perspective Of The Thing

There are 4 activities the product in any process:

1. Storage < 18%2. Transportation < 2%

3. Inspection 04. Processing > 80%

world-classour tendency

70-80%10%

5-10%1-5%

Note: percentages are of process lead-time.

This is an uncommon thought process; education and workexperience typically have us focus on how busy people and equipment are.

Lean thinking has us initially focus on how busy (with valueadded activity) the product is.


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Value Added Activity An activity that Changes the size,shape, fit , form, or function ofmaterial or information (for the 1sttime) to meet customerrequirements.

Non-Value Added Activity All other activities that take timeor resources or does not satisfycustomer requirements

Value Added

Required Waste

Pure Waste

Idle!

Value Added: Customer Values it Changes the THING CORRECT THE FIRST TIME!

Defining Value


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PRODUCT LINE:PART NUMBER: VIDEO TAPE TITLE: PAGE ___ OF __ PART NAME: START TIME ON VCR: PREPARED BY:DATE: START TIME ON TAPE:

NOTE: RECORD ALL TIME IN SECONDS AND DISTANCE IN FEET

Flow Flow Storage Time Transportation Inspection Processing TimeCode Symbol Time Description Raw

Material(RM)

Betw eenProcess

(B)

End ofProcess

(E)Product

(FG)Time(T)

Distance(in feet)

Time(I)

Non-Value Added

(NV)

Value Added

(VA)

Total


Product Process Flow Analysis


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S t o r e s Value Added Steps

Non Value Added Steps

DAY 0 DAY 76

Elapsed Time = 76 Days

Value Added2 Days

Total Activity = 4.5 Days

Non-Value Added2.5 Days

Wait or Queue Steps(White Space)

How do I get

rid of thewhite space?

Time Value Chart


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Time Value Analysis reveals the opportunity! A typical analysis at our facilities indicates that value is being

added to the product around 1% of the time

Time Value Chart AS IS

ACME product # 12345 Elapsed Time = 187 DaysValue Added = 1.83 DaysNon-Value Added Activity = 6.54 DaysNon-Value Added Wait = 179 Days

Time Value Chart TO BE

Elapsed Time = 20 DaysValue Added = 1.83 DaysNon-Value Added Activity = 5.17 DaysNon-Value Added Wait = 13 Days

Rework Loop

Rework Rate

Currently Required Waste

A n o

d i z e

2 %

S t o r e s

I n s p e c

t

Elapsed Time

Value Added

Most of the Lead Time is White Spaceor Product Waiting Time!

Time Value Chart


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Goal is to identify and eliminate waste! Translates to "change for the good". Think "continuous incremental improvement" of a currentstandard. Is a rapidly applied learn/ do approach for Improving. Determine the improvement need/opportunity, then go and do.

Uses a focused workshop format with internal dedicatedresources. Requires planning and commitment. Does not have to be a grand 'event'. Involves the people working in the process.

Next step: Perform a Kaizen event


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activity of product qs- lean manufacturing

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