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Technology Workshop
Utilities
10%
Training & Education 70%
Material – 70%
Eliminate Scrap
Eliminate Inventory
Demand Flow Business Strategy
Cost to the Company
Defect Found At …..
Station 1
One-Down Operation
Out-of-Box
FG’s
Customer
Traditional Mfg. Vs. Demand Flow Mfg.
Scheduling techniques Mathematical
Fabrication &
technology
subassembly Mixed-model flow
production process
Flow line design
Departmental build
Build the product in total
Schedule, queue and work content time or
batch work time less
Material movement Minimum material
External Inspection movement
TQC & verify
Product Synchronization
A relationship of the processes in a flow to
produce a product.
Product Synch
Teams
DFT Activity Sheet Transports MP-3 Stacker-2 Depositor Key/edplt MMD Divert Divert-Tran PPM IDM CASSETTE Bins Prt-A
One up-stream
One down-stream
People (Dr)
Resources are Dc x L
calculated daily to HxS
determine the Money picker
requirement to
produce the daily 50 x .50
rate (8) X (1)
=3.125
3 people
Line Balancing Tools
Tools used when actual time at an operation
exceed TAKT
Relocate work
Reduce or eliminate non-value added work
content
Add resources or duplicate resources
Move inventory and time (Kanban)
Certification
Meet TAKT
Train others
Meet quality criteria
Flex
In-Process Kanban (IPK)
A visual signal that identifies when work
needs to be performed in a line
Kanban Card
A card used as a communications signal
to pull material based on demand
Pull Sequence
Every part that is kanban pulled must
have a definable path that identifies the
supply and consumption points
(e.g Line, Rip, Wip, FG’s)
Mixed Model Line
A primary goal of demand flow manufacturing is
to design flow lines to produce families of
similar products. The mixed model line has
the ability to build a range of volumes of any
product, any day, based on the direction of
actual customer demand.
Backflush
The method used to relieve RIP (Raw in
Process) inventory of a product’s bill of
material quantity when a product is
complete
Communication Lights
Management Light – A light that can be
seen from a wide area to identify if
action needs to be taken on the line
e.g Andon
Measuring Linearity
Example: during a nine-day period the production
rate is (4) per day:
4+4+4+4+4+4+4+4+4=36
Pe ople Dr x L
H x S
TAKT H x S
Dc