Workflow

Continuous Flow
The Traditional Approach

Specialist departments
Delay | Transport | Storage

Long distances
Operation 3
Long lead times
Operation 2 Operation 1
Big batches
High WIP

Operation 4 High
g cost
Operation 5 Poor problem
solving & team
spirit

Operation 6 Operation 7

2
Dedicated Line Solution

Operation 3
Operation 2 Operation 1
ELIMINATE
Operation 4
the delays
p
Operation 5
the transport
Operation 6 Operation 7 and storage times

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

thanks to parts families and dedicated lines

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

rather than diffused lines

Operation 1 Operation 4 Operation 5 Operation 2 Operation 5 Operation 7
Steps to implement dedicated lines
Define PARTS FAMILIES
Design IDEAL DEDICATED LINES
Find solutions to ACTUAL CONSTRAINTS
Find solutions to ORPHAN PARTS
Design REALISTIC DEDICATED LINES
Find solutions to MEET THE DEMAND
Implement dedicated lines and
ONE-PIECE FLOW
Operation 6 Operation 1 Operation 6 Operation 5 Operation 2 Operation 7

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

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

Define parts families based on
High volume (80/20)
High
Hi h value
l (80/20)
Similar by
th
the fform
the material
the process sequence
Runners, repeaters and strangers
Create Process Families

Parts
STEP 1
A X X X X

B X X X X Identify the
C X X X X parts and their
p
D X X X X X X process
E X X X X X X
F X X X
G X X X
Create Process Families

Parts
STEP 2
A X X X X
Identify
B X X X X
similar
C X X X X
processes
D X X X X X X
E X X X X X X
F X X X
G X X X
Create Process Families

Parts
STEP 3
A X X X X
Create parts
D X X X X X X
family by
E X X X X X X
G X X X
processes
B X X X X

C X X X X
F X X X
Analyse the Processes
Plant: Team: PARTS/PROCESS MATRIX Date:

Machine Auto Single Multi Multi Milling Wash Milling Broach

Cutter Drill spindle
i dl hi
machine Rolling Gear machine
hi l th
lathe
No lathe purpose dl
spindle tank
lathe drill tapping machine hub

Cutting Lathe Lathe cut Drilling Cham- Screw Milling Clean- Rolling Debur- Gear Milling Drilling
Process cutting 2 fering cuttin ing ing teeth
cutting

Qty Part #

1 9985M26

2 9176M25

3 9383M42

4 9522M60

5
9522M58

9522M50
6

10
Align the processes to optimise families

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

Parrt A
6 7 8

1 2 3
Part B
COMBINE 4 5 6 7
Part C

1 2 3

4 5 6
SIMPLIFY
A, B & C
Parts

1 2 3 4 5 6
P
Steps to implement dedicated lines
Define PARTS FAMILIES
Design IDEAL DEDICATED LINES
Find solutions to ACTUAL CONSTRAINTS
Find solutions to ORPHAN PARTS
Design REALISTIC DEDICATED LINES
Find solutions to MEET THE DEMAND
Implement dedicated lines and
ONE-PIECE FLOW
Design ideal dedicated lines
One line per parts family
Th shortest
The h path
h from
f raw materials
i l to fi
finished
i h d part iincluding
l di
every operation
every function
support activities
specialised activities

The total linkage of all operations and functions required to make a

part (everything is linked by an imaginary conveyor)
Dedicated equipment and dedicated workers in a dedicated place
U shaped flow line Op 4
Op 3 Op 5

Op 2 Op 6

Op 1 Op 7
Find actual constraints

Op 5

Op 4
Op
p3 O 4
Op O 4
Op

Op 2 Op 6

Op 1 Op 7

External operation Shared operation

Supplier operation Expensive equipment
Immoveable plant/equip Limited skills
Infrequent operation Similar characteristics
Close proximity
 Find solutions to actual constraints
Op 5 Op 4

K Op 3 Op 5
Op 4
Op 3
Op 2 Op 6

Op 2 Op 6
Op 1 Op 7 Op 4
Op 4

Op 1 Op 7

Op 4
Op 5

Op 4
O 3
Op Op 5

Op 2 Op 6

Op 1 Op 7

External operation Shared operation

JIT with supplier Share equipment (shifts,
(shifts schedule)
Move cell to plant/equip Retrain or move the skills
Moveable equipment Modify for both characteristics
Move together proximity
Find solutions to orphan parts
Can a dedicated line adopt them ?
Sh ld a jjob
Should b shop
h liline b
be created
t d?
Can we use moveable equipment and flexible lines ?
Should they be outsourced ?
Etc.
Design realistic dedicated lines

Fishbone
Line

U Line

L Line
Back to Back
Lines
I Line
Steps to implement dedicated lines
Define PARTS FAMILIES
Design IDEAL DEDICATED LINES
Find solutions to ACTUAL CONSTRAINTS
Find solutions to ORPHAN PARTS
Design REALISTIC DEDICATED LINES
Find solutions to MEET THE DEMAND
Implement dedicated lines and
ONE-PIECE FLOW
Batch vs 1 Piece Flow

Batches and delays

One-piece flow
Batch vs Flow (Push vs Pull)

5 parts
2 h/ partt
= 10 h
A
= 10 h
B
= 10 h
C
= 10 h
D
First
good
part
H
How tto
eliminate
storage, transport and
0.0 10.0 20.0 30.0 32.0
Batch processing builds large stocks delay wastes ?
1 part First good part
2 h/ part
2 h 2 h 2 h 2 h
Second
One
A B C D good part
Piece
Flow
0.0 2.0 2.0 4.0 4.0 6.0 6.0 8.0 8 0 10.0
8.0 10 0
One piece flow eliminates delays and waiting time
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

Solution

TAKT =
420 mins /day= 70 min/part
6 parts /day
Example Production Line

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

TAKT time
i = 70
0 minutes
i
Cycle time operation 1 = 70 minutes
Cycle time operation 2 = 40 minutes
Cycle time operation 3 = 50 minutes
Cycle time operation 4 = 90 minutes
Cycle time operation 5 = 80 minutes

Part
Op 5 Op 4
completed

Op 3 Customer Takt time

Process time of
each operation
p
Raw Op 1 Op 2
material
Line Balancing
TAKT: 70 MINUTES
Part
completed Op
p5 Op
p4
= 1 part every 70 minutes
Op 3
Process capacity of the line
Raw Op 1 Op 2
= 1 partt every 90 minutes
i t
material

??? 0 20 40 60 80 100 120

Op 1
Op 2
Op 3
Op 4
Op 5 = set-up time
CYCLE TIME DIAGRAM = production time
Line Balancing
TAKT: 70 MINUTES
Part
completed Op
p5 Op
p4
= 1 part every 70 minutes
Op 3
Process capacity of the line
Raw Op 1 Op 2
= 1 partt every 90 minutes
i t
material

??? 0 20 40 60 80 100 120

Op 1
Op 2
Op 3
Op 4
Op 5 = set-up time
CYCLE TIME DIAGRAM = production time
Line Balancing
TAKT: 70 MINUTES
Part
completed Op
p5 Op
p4
= 1 part every 70 minutes
Op 3
Process capacity of the line
Raw Op 1 Op 2
= 1 partt every 90 minutes
i t
material

OK 0 20 40 60 80 100 120

Op 1
Op 2
Op 3
Op 4
Op 5 = set-up time
CYCLE TIME DIAGRAM = production time
 Summary
Operation 3
Operation 2 Operation 1
ELIMINATE
the delays
Operation 4
Operation 5
the transport 1 Set-up
1. Set up dedicated lines
Operation 6 Operation 7 and storage times

Operation 6 Operation 1 Operation 6 Operation 5

thanks to parts families and dedicated lines

Operation 2 Operation 7
2. Implement 1 piece flow
Operation 1 Operation 2 Operation 4 Operation 1 Operation 6 Operation 7

Operation 1 Operation 4 Operation 5

rather than diffused lines
Operation 2 Operation 5 Operation 7 Batches and delays
3. Balance the line to the
Takt time

TAKT: 70 MINUTES
One-piece flow Part Op 5 Op 4
completed
= 1 part every 70 minutes
Op 3
Process capacity of the line
Raw Op 1 Op 2
= 1 part every 90 minutes
material

OK 0 20 40 60 80 100 120

Op 1
Op 2
Op 3
Op 4
Op 5 = set-up time
C C TIME DIAGRAM
CYCLE G = production
d ti ti time