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Agenda
Basics of Value Stream Mapping Product Family Current State Map Lean Basics Future State Map Plan
Copyright Manos/Alukal 2002
Section 1
Project Initiation Product Family Current State Map Case Study
Benefits of VSM
Helps you visualize more than the single process level Links the material and information flows Provides a common language Provides a blueprint for implementation More useful than quantitative tools Ties together lean concepts and techniques
Copyright Manos/Alukal 2002
Determine the Product Family Draw your Current State Map Create the Future State Map Develop your plan to get there
VSM is not
VSM Team
Typically a cross-functional team of managers or supervisors Team size 7-10 people Have experienced VSM person lead the session Have to walk the flow Commit to the time requirement
Copyright Manos/Alukal 2002
Poka-yoke
POUS Batch Size Reduction Quick Changeover Layout Standard Work Visual 5S Teams
Change Management
Copyright Manos/Alukal 2002
Multiple Facilities Plant One Facility Good place to start Process Process Division Plant
HQ
Process
Scope Example
Product Family
Process Steps & Equipment
Drill Right Handle Left Handle Body Base Insert Switch Weld Stamp Paint Manual Assbly Fixture Assbly
Test
X X X X X
X X X
X X
X X X X X X
Products Products
X X
Copyright Manos/Alukal 2002
Product Family
Process Steps & Equipment
Drill Right Handle Left Handle Body Base Insert Switch Weld Stamp Paint Manual Assbly Fixture Assbly
Test
X X X X X
X X X
X X
X X X X X X
Products Products
X X
Copyright Manos/Alukal 2002
Process Box
Painting
Go See
Quality
Train
&@#$%!
Class Exercise
Case Study Goodenuff, Inc. Produces toy fire engines Traditional Manufacturer Having problems lately with on-time delivery and customer satisfaction
Copyright Manos/Alukal 2002
Title Block
Process Flow
Stamping
Stamping
Stamping
Spot Weld
Stamping
Spot Weld
Deburr
Stamping
Spot Weld
Deburr
Assemble
Stamping
Spot Weld
Deburr
Assemble
Stamping
Spot Weld
Deburr
Assemble
C/T=1 sec
Stamping
Spot Weld
Deburr
Assemble
Stamping
Spot Weld
Deburr
Assemble
Stamping
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% C/T= C/O= Rel.= FPY =
Copyright Manos/Alukal 2002
Stamping
Shared
Spot Weld
Deburr
Assemble
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Copyright Manos/Alukal 2002
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Spot Weld
Deburr
Assemble
Stamping
Shared
Deburr I =1 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld
Deburr
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Deburr
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I
Deburr
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Information Flow
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% I 1,400
Deburr I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 1,225
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90%
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 39 sec
Assemble
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 39 sec
Assemble
10 days
1 sec
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Assemble
=1 C/T=1 sec
5,425 C/T=39 sec C/O= 4 hrs 265 C/O= 11 min Rel.= 98% = 20.47 Rel.= 99%
FPY = 90% 39 sec
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Assemble
=1 C/T=1 sec
5,425 C/T=39 sec C/O= 4 hrs 265 C/O= 11 min Rel.= 98% = 20.47 Rel.= 99%
FPY = 90% 39 sec 20.5 days
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
10 days
1 sec
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 105 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
10 days
1 sec
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
10 days
1 sec
Stamping I 2 Weeks
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
1,400
10 days
1 sec
Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
10 days
1 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
Assemble
10 days
1 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
1,225
10 days
1 sec
4.5 days
48 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
1,225
10 days
1 sec
4.5 days
48 sec
20 min Order Entry MRP Monthly Weekly Dewey, Cheatem & Howe Daily Assemble I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
PhlyeBiknight Weekly
Information Flow
L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400
Spot Weld I 5,425 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
10 days
1 sec
20 min Order Entry MRP Monthly Weekly Dewey, Cheatem & Howe Daily Assemble I =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
PhlyeBiknight Weekly
Information Flow
L/T= 2 days P/T = 20 min Daily Deburr I =1 1,400
Spot Weld I 5,425 C/T=39 sec Rel.= 99% FPY = 90% 39 sec
10 days
1 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
1,225
10 days
1 sec
4.5 days
48 sec
TPS
Lean (US)
100
Definition of Lean
Lean has many definitions A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection
- Definition by the MEP Lean Network
Give the customer what they want, when they want it and dont waste anything.
Copyright Manos/Alukal 2002
8 Wastes of Lean
OMIT What U DO
Overproduction Motion Inventory Transportation Waiting Underutilized People Defects Over-processing
Copyright Manos/Alukal 2002
Overproduction
Making more-earlier-faster than the next process needs it.
Just in case logic Unbalanced workload Unleveled scheduling
Motion
Any movement of people or machines that does not add any value to the product or service Poor layout Inefficient Workplace Organization Lack of Standardization, inconsistent work methods People, Material and Machine Ineffectiveness
Copyright Manos/Alukal 2002
Inventory
Any supply in excess of one-piece flow Just in case logic Unbalanced workload Unleveled scheduling Unreliable suppliers Reward system
Transportation
Moving people, materials and information around the organization
Poor layout Inefficient flow Carrying large inventories
Waiting
Waiting for man, machine, materials, information etc.
Just in case logic Unbalanced workload Unleveled scheduling Unplanned downtime
Underutilized People
Not utilizing peoples experience, skills, knowledge, creativity.
Not utilizing Teams Organization structure Poor hiring practices Little investment in training
Defects
Rechecking or re-inspecting work
Not using Jidoka or Poka-yoke Lack of Standardization, inconsistent work methods Ineffective communication Little investment in training
Over-processing
Effort that adds no value to the product or service from the customers (internal or external) standpoint Just in case logic Inconsistent work methods Ineffective communication Redundant approvals Excessive information, extra copies
Copyright Manos/Alukal 2002
Poka-yoke
POUS Batch Size Reduction Quick Changeover Layout Standard Work Visual 5S Teams
Change Management
Copyright Manos/Alukal 2002
Change Management
Lean is not a quick fix Lean is not for everyone Incremental and Breakthrough improvements Prepare and motivate people Employee involvement Identify Champions Reward and recognition What if we dont get better and our competition does?
Copyright Manos/Alukal 2002
Lean Teams
Cooperative instead of competitive Cross-trained Cross-functional Improvement teams are examples of creativity before capital Input and involvement valued by management Pooling of team skills, talents and knowledge Mutual support for each other
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Sort
When in doubt, move it out
Move unneeded items out of the area Use the Red Tag Technique Use a Temporary Red Tag Holding Name____ Date___ Area Criteria for unneeded items Item _____________ Reason _________ 30-day Rule Keep only what you need in the area
Copyright Manos/Alukal 2002
Set in Order
A place for everything and everything in its place.
Make it easy for anyone to find 30-second Rule Make it obvious if an item is out of place Decide where to keep items, how many items to keep, how and when to replenish items Make it visual
Shine
Clean and Inspect
Get items to a like-new condition 10 Second Rule Must plan Shine assignments & supplies Perform as a Team Prevent dirt, grime, or contamination Repair as needed
Copyright Manos/Alukal 2002
Standardize
Create the rules and follow them
Determine how the first 3S conditions are met Use One-Point Lessons Maintain and monitor the conditions Use visual techniques
Copyright Manos/Alukal 2002
Sustain
Make 5S a habit
5S is not something additional, it is part of everyones daily job Supports discipline Train Communicate Support from Management Reward and recognition
Copyright Manos/Alukal 2002
5S in the Office
After
Before
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Visual
Signs, lines, labels and color coding
Why Visual?
What you need to know Cockpit view Information sharing How do you know where to park when you drive your car to work? Does your boss have to tell you where to park?
Copyright Manos/Alukal 2002
Visual Examples
Shadow Boards
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Standard Work
Reduce task variability
Standard Work
Best Sequence of Operations Man, machine, materials, changeovers, etc. Identifies value added versus non-value added activities Reduce or eliminate NVA activities Convert internal time to external time Use for continuous improvement
Copyright Manos/Alukal 2002
Time
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Layout
Streamlined Layout
Streamline Layout
Flow by product family the output of one process is the input for the next Created with input from employees Flexible, easy to change Short distances, small batches Visual, good communication Concentrate on reducing waste and non-value added activities like Motion & Transportation
A B C
Assembly Support
Assembly Machining
Support
Traditional Factory Capacity 125,000 Copyright Manos/Alukal Factory Size (Sq ft) 2002 500,000
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Point-of-Use-Storage
Keep it where you use it
Point-Of-Use Storage
Raw material and WIP are stored at workstation where used, which reduces the inventory that can be carried Works best if vendor relationship permits frequent, on-time, small shipments (JIT) Simplifies physical inventory tracking, storage, and handling
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
2 + 10 min
2 + 10 min + + 1 min
1 min
Batch Size = 1
1 min
First Piece
Defect Detection
Improvements
30 21 11 12 3 Flow
60%
86%
91%
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Quick Changeover
Changeovers in less than ten minutes
A
Monday
B
Tuesday
C
Wednesday
D
Thursday
E
Friday
1 hour C/O
9 8 7 6 5 4 3 2 1 0
B A
Monday
D C
Tuesday
A E
Wednesday
C B
Thursday
E D
Friday
Monday
Tuesday
Wednesday
Thursday
Friday
1 Hour C/O Hour C/O 30 hours 34.5 hours 10 hours 5.5 hours 10 11
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Explanation
Autonomation (Jidoka) Requires operator intervention if an error occurs Self Inspection Operator is responsible for the quality of their work Poka yoke Error-proofing, prevents an error from occurring
Copyright Manos/Alukal 2002
Autonomation
A technique to ensure that only good parts are produced and passed on; this defect detection system manually (human automation) or automatically stops production if a problem occurs Will have a device to detect errors or abnormalities Will have a device to automatically shut down machine if a defect occurs
Copyright Manos/Alukal 2002
Autonomation Example
Sensors determine if an element is correctly in place The machine automatically stops if an element is missing This ensures that all parts (100%) have an element inserted
Sensors
Self Inspection
The operator is responsible to ensure a defective part is not passed to the next operation Training, tools, standards must be provided to the operator Use SPC or other mechanisms of feedback Design quality into the system versus detection
Copyright Manos/Alukal 2002
Poka-yoke
Error proof (mistake proof) takes away the possibility of human error The term Poka-yoke was made popular by Shigeo Shingo Fail-safe devices Low cost, highly reliable mechanisms Detects abnormal situations before they occur, or Once they occur, will stop the equipment from further production. The machine stoppage makes the problem visible.
Copyright Manos/Alukal 2002
Poka-yoke Example
The plastic tray is designed to have a notched corner When material is placed into the machine, the pins prevent it from being inserted incorrectly This ensures 100% correct orientation
Locator Pins
Notched corner
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Evolution of TPM
TPM
Older times
Now
What is TPM?
A Lean maintenance strategy for maximizing equipment reliability and uptime Share responsibility for equipment reliability Eliminate equipment related waste: Unplanned downtime Planned downtime Changeovers Minor stoppage Speed reduction Poorer quality product Idled equipment
Copyright Manos/Alukal 2002
OEE Calculation
OEE = Availability x Performance x Quality
Breakdowns Setup Tool changes Idled time Not at rated speed Minor stoppages Defects Rework Start-ups
Examples
Number of Uptime Standard Number of Scheduled x Cycle Time x Pieces Produced x Good Pieces Total Number Production Uptime Produced Time
Copyright Manos/Alukal 2002
OEE Example
OEE Example for 4 linked machines
OEE 78% OEE 33% OEE 45% OEE 63% Overall OEE 7%
.78
.33
.45
.63
= .073
World Class OEE Measures Discrete Part Manufacturing = 85% Continuous Processing = 92%
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Cellular/Flow
Definition: Linking and arrangement of manual and machine process steps into the most efficient combination to maximize valueadded content while minimizing waste.
Copyright Manos/Alukal 2002
Cellular/Flow
Value is added any time we physically change our product towards what the customer is buying. If we are not adding value, we are adding cost or waste. Flow Manufacturing drives the systematic elimination of waste. Will help in collapsing the lead time closer and closer to actual value-adding processing time. Cellular/Flow production results in no WIP, no Waiting.
Copyright Manos/Alukal 2002
In
C/T = 45s
C/T = 30s
Process 6
Out
Process 10
Process 9
Process 8
In
C/T = 45s
C/T = 30s
Process 6
Out
Process 10
Process 9
Process 8
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Pull System
Replenish at the Demand of the Customer
Pull Based on Actual Customer Usage Only produce when product is consumed
Pull
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Kanban
Kanban = Sign, signal Order point when to replenish the supermarket Order quantity the amount to replenish the supermarket
Order Quantity =2
Process B Process A
In this example, Process A can produce faster than what Process B needs.
Order Point =4
Copyright Manos/Alukal 2002
6 Kanban Rules
You cannot send bad product to the next operation Only withdraw what is needed Only produce what is used Smooth the workload Standardize Keep improving
Copyright Manos/Alukal 2002
Supermarkets
When a supermarket shelf is full, you cant fill it any more When a supermarket shelf is at the order point, you fill it It is a controlled inventory Calculate the correct size and audit as needed
C D
JIT
JIT= Just in time JIT is not just for your Suppliers, you must perfect JIT within your own operations JIT is the opposite of Overproduction Delivery just before the next operation needs it Dont make it earlier, faster, or before it is needed
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124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Continuous Improvement
Continuous Improvement (C. I. or Kaizen, in Japanese), is an essential and never ending process
Employee suggestions Corrective & Preventive actions Non-conformities, defects Customer complaints, returns Benchmarks The Lean wastes Variations from the standard Assessments, audits & competitive analyses Research & Development activities
Copyright Manos/Alukal 2002
124 W. Polk Street, Suite 101 Chicago, Illinois 60605-2770 Tel 312-294-9900 Fax 312-294-9911 www.proferoinc.com
Kaizen Blitz
Breakthrough Strategies for Lasting Results
+ ZEN
For the better
KAIZEN
Continuous Improvement
BLITZ
Flash or Lightning
Kaizen Blitz is Service Marked by AME (Association for Manufacturing Excellence)
Copyright Manos/Alukal 2002
Kaizen Blitz is a combination of the Japanese word Kaizen for continuous improvement and the German word Blitz for lightning It is a focused, typically week long project where a cross-functional team reviews a process, identifies and eliminates waste, thereby achieving dramatic & tangible BREAKTHROUGH (rather than incremental) improvement results Also called, Rapid Kaizen, Kaizen Event, etc.
Copyright Manos/Alukal 2002
It is treated more as a Project and not as a Process For Kaizen Blitzes to succeed, Top Management commitment is critical Kaizen Blitzes are aligned with companys strategy Creativity before Capital is the motto
Copyright Manos/Alukal 2002
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
1,225
10 days
1 sec
4.5 days
48 sec
8.
What is the Takt Time? Will we build to shipping or to a supermarket? Where can we use continuous flow? Where do we have to use supermarket pull system? At what single point in the production chain do we trigger production? How do we level the production mix at the pacemaker process? What increment of work will we release and take away at the pacemaker process? (Leveling the volume) What process improvements will be necessary? (e.g. uptime, changeover, training)
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Build to Shipping
We can take the customer order Receive the raw materials Produce the product Ship the product All in less than the delivery date required by the customer
Copyright Manos/Alukal 2002
Build to Supermarket
We cannot take the customer order Receive the raw materials Produce the product Ship the product All in less than the delivery date required by the customer
Copyright Manos/Alukal 2002
Supermarkets
Supermarkets are controlled inventory Think of the supermarket shelf
When it is low, it is filled up When it is full, no more is produced Bread man story
Mon
A A A A A
Tue
A B B B B
Wed
C C C C C
Thur
C C C D D
Fri
D D D D D
=6 =4 =8 =7
What do you tell Customer D if they want parts on Monday? Are these jobs repetitive and boring? What happens if Customer A calls Monday afternoon and cancels the order?
Copyright Manos/Alukal 2002
Mon
A B C C D
Tue
A B C D D
Wed
A B C C D
Thur
A B C C D
Fri
A A C D D
=6 =4 =8 =7
7. What increment of work will we release and take away at the Pacemaker process?
Pitch
Management intervention time frame
Know the pitch time increment Know when a problem occurs Respond quickly Element Paced withdrawal Material Handler time frame or milk run
Pack-out quantity
Kaizen Event
L/T= 2 days P/T = 20 min Daily Deburr I =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec
Assemble I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 4.5 days 48 sec 40 days 105 sec
10 days
1 sec
20.5 days
39 sec
A. 95 seconds
Stamping I
Shared
Assemble I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
2 Weeks
10 days
1 sec
A. 95 seconds
Stamping I
Shared
2 Weeks
m to e bl uild o e Deburr pr t b Assemble im t o irs ann kt T . o F c Ia T s ec ed t e e W t1,225 5 ne he h 9 =1 t ill ve =2 e e w pC/T=48m ro Ti sec C/T=17 sec W im C/O= 5 min cle C/O= 0 min Cy
Rel.= 100% FPY = 98% 48 sec 4.5 days 40 days 105 sec
10 days
1 sec
Monthly Q2. Build to Shipping or Build to a Supermarket? Dewey, MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily Deburr I =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec 1,400 =1 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days I 1,225 =2 C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
Assemble
10 days
1 sec
Weekly
Daily A. Our customers require delivery in less time ofStamping our ordering raw materials and making Spot Weld Deburr Assemble Shared the product. I I I I
2 Weeks
=1
5,425
=1
1,400
1,225
10 days
1 sec
4.5 days
48 sec
Weekly
Daily A. Our customers require delivery in less time ofStamping our ordering raw materials and making Spot Weld Deburr Assemble Shared the product. I I I I
2 Weeks
=1
5,425
=1
1,400
1,225
10 days
1 sec
4.5 days
48 sec
Q.3 Where can we flow? PhlyeBiknight Weekly Weekly Schedule Stamping I 2 Weeks
Shared
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
1,225
10 days
1 sec
4.5 days
48 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Deburr Monthly Weekly
5,300 pcs/mo. 265 pcs/day
Dedicated equipment
Stamping I
Shared
Spot Weld I 5,425 =1 C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec I 1,400
Assemble I
2 Weeks
1,225
10 days
1 sec
4.5 days
48 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
Create a Cell
SW/Deburr/Assemble
I C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec
=4 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
10 days
1 sec
PhlyeBiknight Weekly
2 Weeks
10 days
1 sec
20 min Order Entry MRP L/T= 2 days P/T = 20 min Daily Monthly Weekly
5,300 pcs/mo. 265 pcs/day
PhlyeBiknight Weekly
SW/Deburr/Assemble I C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec =4 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
10 days
1 sec
Monthly Q4. Where do we use a Supermarket Pull System? Dewey, MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble I C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec =4 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
10 days
1 sec
Weekly
2 Weeks
10 days
1 sec
Weekly
I 2 Weeks
Shared
10 days
1 sec
Monthly Q4. Where do we use a Supermarket Pull System? Dewey, MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble I C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec =4 C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
10 days
1 sec
Monthly Q4. Where do we use a Supermarket Pull System? Dewey, MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble =4 =1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
Monthly Q4. Where do we use a Supermarket Pull System? Dewey, MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble =4 =1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec Weekly
5,300 pcs/mo. 265 pcs/day
Weekly
Q5. Where do we trigger production? MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble =4 =1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec Weekly
Monthly Weekly
5,300 pcs/mo. 265 pcs/day
C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 4.5 days 48 sec 40 days 105 sec
Q5. Where do we trigger production? MRP PhlyeBiknight L/T= 2 days P/T = 20 min Daily SW/Deburr/Assemble =4 =1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec Weekly
Monthly Weekly
5,300 pcs/mo. 265 pcs/day
C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 4.5 days 48 sec 40 days 105 sec
PhlyeBiknight
Monthly Weekly
5,300 pcs/mo. 265 pcs/day
SW/Deburr/Assemble =4
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
Weekly
SW/Deburr/Assemble =4
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
Weekly
SW/Deburr/Assemble =4
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
Weekly
SW/Deburr/Assemble =4
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
Weekly
OXOX
SW/Deburr/Assemble =4
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
OXOX
Stamping
Shared
Daily SW/Deburr/Assemble =4
OXOX
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
OXOX
Stamping
Shared
Daily SW/Deburr/Assemble =4
OXOX
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
OXOX
A. Based on our customers requirements and SW/Deburr/Assemble Stamping the pack-out quantity Shared =4 12 boxes per case Pitch=1 12 boxes per case x 95 sec per unit = C/T=1 sec C/T=39 sec C/T=17 sec C/T=48 sec = 19 minutes
C/O= 4 hrs Rel.= 98% FPY = 95% 1 sec C/O= 11 min Rel.= 99% FPY = 90% 39 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 10 days 20.5 days 5 days Copyright Manos/Alukal 2002 4.5 days
Daily
OXOX
C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
OXOX
Stamping
Shared
Daily SW/Deburr/Assemble =4
OXOX
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec 4.5 days C/T=48 sec C/O= 5 min Rel.= 100% FPY = 98% 48 sec 40 days 105 sec
PhlyeBiknight
OXOX
Stamping
Shared
Daily SW/Deburr/Assemble =4
OXOX
=1 C/T=1 sec C/O= 4 hrs Rel.= 98% FPY = 95% 10 days 1 sec C/T=39 sec C/O= 11 min Rel.= 99% FPY = 90% 20.5 days 39 sec C/T=17 sec C/O= 0 min Rel.= 80% FPY = 100% 17 sec C/T=48 sec C/O= 5 min C/T = Rel.= 100% 104 sec FPY = 98% 40 days 4.5 days 48 sec 105 sec
PhlyeBiknight Weekly
OXOX
Stamping
Shared
OXOX
20.5 days
PhlyeBiknight Weekly
OXOX
Stamping
Shared
OXOX
20.5 days
Weekly
OXOX
Stamping
Shared
OXOX
20.5 days
Weekly
OXOX
Stamping
Shared
OXOX
As an estimate, how much 20 min P/T = Weekly OXOX inventory do we want to keep Daily in the Supermarkets?
Scheduling Stamping
Shared
Biknight
L/T= 2 days
Daily
OXOX
SW/Deburr/Assemble =4
=1 C/T=1 sec Stamping C/O= 4 hrs C/O = 4 hrs Rel.= 98% FPY = 95% C/T=39 sec C/O= 11 min Rel.= 99% SW FPY FPY90% = = 90% C/T=17 sec C/O= 0 min Deburr Rel.= 80% Rel. = 80% FPY = 100% C/T=48 sec C/O= 5 min C/T = Rel.= 100% 104 sec FPY = 98%
As an estimate, how much 20 min P/T = Weekly OXOX inventory do we want to keep Daily in the Supermarkets?
Scheduling Stamping
Shared
Biknight
L/T= 2 days
Daily
OXOX
SW/Deburr/Assemble =4
=1 3 days C/T=1 sec Stamping C/O= 4 hrs C/O = 4 hrs Rel.= 98% FPY = 95%
2 days
C/T=17 sec C/O= 0 min Deburr Rel.= 80% Rel. = 80% FPY = 100%
2 days C/T=48 sec C/O= 5 min C/T = Rel.= 100% 104 sec FPY = 98%
Weekly
OXOX
Stamping
Shared
OXOX
3 days
2 days
Weekly
OXOX
Stamping
Shared
OXOX
3 days
2 days
Weekly
OXOX
Stamping
Shared
OXOX
3 days
2 days
PhlyeBiknight Weekly
OXOX
Stamping
OXOX
3 days
2 days
PhlyeBiknight Weekly
OXOX
Stamping
OXOX
3 days
2 days
Scheduling
OXOX
Stamping
OXOX
3 days
2 days
Scheduling
OXOX
Stamping
OXOX
3 days
2 days
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
Measurable Improvement
Lead-time 40 days Cycle time 105 sec Inventory 10,700 pcs Kaizen events
Stamping changeover time Deburring reliability Spot weld quality Operators in cell cross-trained More flexibility Reduced lead-time and defects = happier customers
Copyright Manos/Alukal 2002
Other benefits
Break it into manageable sizes Too many loops may cause confusion
Number of Loops
Make it manageable Not too may Not too few Look for logical breaks Thumb rule
Probably somewhere between 3-7 loops
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
Scheduling
OXOX
Stamping
OXOX
3 days
2 days
Loop 1
Monthly Daily
5,300 pcs/mo. 265 pcs/day
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
Loop 1
Monthly Daily
5,300 pcs/mo. 265 pcs/day
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
Loop 1
Monthly Daily
5,300 pcs/mo. 265 pcs/day
Scheduling
OXOX
Stamping
Shared
OXOX
3 days
2 days
The Plan
People dont plan to fail, they fail to plan.
Project Management
Define and plan the project activities Track the progress Manage schedules, resources, costs, scope and risk Report the project status Perform a final review, closeout and lessons learned Plan for resources such as Costs Quality Risks Communication Human resources Scope Time Procurement
Types of Actions
Project
Subproject
Tasks
Plan Obstacles
Beware! People may not want to commit themselves or their resources Remember not to optimize one area while sub-optimizing another area Overall efficiency is the goal, not individual efficiencies Dont overload the front end of the project
Copyright Manos/Alukal 2002
Planning Matrix
Use a Planning Matrix, Gantt Chart or something similar to document the planning effort Show the steps, time table and responsibility
SIGNATURES
MONTHLY SCHEDULE
PLT MGR
ENG
MAINT
CONTINUO US FLOW FROM WELD ASSMBLY STAMPING PULL STAMPING C/O PULL FOR COILS WITH DAILY DELIVERY
ZERO WIP
The Plan
VS Loop
VS Objective
GOAL (Measurable)
Time Frame
Leader
Other Depts.
Zero Wip
Remember, this is whats best for the Value Stream not a manager or department
Copyright Manos/Alukal 2002
Communicate progress
The Value Stream Manager walks the floor to gather progress information Communicate the progress to the Work teams, Champions and Design teams Post results on the communication board
Copyright Manos/Alukal 2002
Communication is Key
As part of good Change Management, we must communicate consistently and constantly Fear of the unknown produces anxiety about the change Use the Current State Map, Future State Map, Plan and Review to communicate Communicate, communicate, communicate!
Copyright Manos/Alukal 2002
Communication Example
Communication Board
VSM Manager VSM Team VSM Current State VSM Future State Value Stream Plan Value Stream Review
Value Stream Board Current Plan Future Team
Review Notes
Additional Information
The Value Stream Manager Examples of information flow in support areas Communication Value Stream Life Cycles
Information Flow
Support areas or functions may look at information differently than the shop floor Substitute Processing Time (P/T) for Cycle Time (C/T)
Ask the question If you had no interruptions, how long would it take you to finish this task?
Use Lead Time (L/T) for the amount of NVA time, waiting or batching of tasks
Ask How long before this paperwork moves to the next process step?
Copyright Manos/Alukal 2002
Benefits of VSM
Helps you visualize more than the single process level Links the material and information flows Provides a common language Provides a blueprint for implementation More useful than quantitative tools Ties together lean concepts and techniques
Copyright Manos/Alukal 2002
Conclusions
Practice VSM every chance you get You must have a plan! Focus on achieving the Future State
Questions?
Wrap-up Evaluations
Thank you
Copyright Manos/Alukal 2002
Contact Information
Tony Manos Catalyst Do not hesitate to contact me if you have Profero, Inc. any comments or 124 W. Polk Street, Suite 101 questions. Chicago, IL 60605-1770 I wish you great success! USA Office: 312.294.9900 Cell: 312.718.0078 Fax: 312.294.9911 Email: anthony.manos@proferoinc.com Website: www.proferoinc.com 2002 Copyright Manos/Alukal