Agile Manufacturing

LOGO
Agile
Manufacturing
Presented by: Section B -
Group 8
Amit Matani
R Karthik
Rahul Sharma
Ravi Gupta
Tisa Annie Paul
Agile Manufacturing – Introduction
Mass Lean Agile

Manufacturing Manufacturing Manufacturing
Ford , Toyota , USA / Europe

USA Japan
Agile Manufacturing
Agile manufacturing is a method for manufacturing which

combines the entire organization, people and technology
into an integrated and coordinated system
An overall enterprise strategy focused on thriving in an
environment of unpredictable change
Effects of Manufacturing Shifts
Craft Mass JIT Agile
Craft Mass JIT Agile
Sensitivity to customer High Low Medium

demands High
Cooperation between Medium Low Low High
companies
Creativity of Increased Decreased Increased Increased
employees
Five Key Steps to Agility
5
1
Customers
Product Design
3
Supplier
Agility
Management
2
Production 4
System Distribution
System
Customer
Interface
Product Production Suppliers Distribution Customer
Auto Industry
NIKE – Shoe Industry

BMW-MINI ROOF DESIGN



FREDDY & MA PURSES

MARIE - SANDALS
ELITE VINTNERS – Wine Industry

3D Scanning
Scanning and processing

3D Printing
Rapid prototyping
Analyze Proposed Systems Prototype Panels

It
er
at Get Feedback
Specify Requirements io
n
s
Improve Prototype Code
Design System Rapid Prototyping
Process
Covert Prototype Code to Actual Code
Develop System
It
er
at Get Feedback
io
n
Release Product
s
Improve Actual Code
Agility in Supplier Relations
Supplier base be rationalised
Limited number of strategic

suppliers
SUPPLIER
RELATIONSHIPS Linked systems and processes
High level of shared information
Multiple collaborative working

relationships
Supplier Side Agility – Mobile OS

Supplier Replacement
Agile Network – Nokia (India)

Promoti
on
Design & & Sales
Developmen
R t C
A U
W S
Finished T
Goods
M Manufacturi O
ng
A M
T E
India
Supplier
L Plast
Distribu Warehousin Retaili R
ics tion g ng
S S
Materia Component
ls s
Supply Supply
After - Servic
Flow of Sales e
material , Support Center
infor mation , s
money , and
knowledge
Postponement
The aim of the agile supply chain is to carry

inventory as generic as possible
Increases the efficiency of the supply chain by

moving product differentiation closer to the end user
Reduces the risk of -

Stock outs
Excess Inventory
Reduces total cost

Increases variety
Agility in Distribution Networks
Fewer stock-keeping variants
Generic inventory,
means greater flexibility
Advantages of Postponeme
Forecasting is easier
Mass Customisation in true terms

IKEA - Furniture
IKEA - Furniture
IKEA - Furniture
Paints Industry
DELL – User Interface

Select Your Own Trim

Select Your Vehicle Options

Thank You!!!
Where does Agile stand?
Lean vs Agile
Lean Agile
Make to stock Make to order

Comparisons
Low variety High variety
Mass, repetitive Product

Innovator
Cost minimizer Customer intimate
Make to forecast Stock Make to order

(to decouple)
Material Lean Agile Customer
suppliers Lean Agile
Lean vs Agile
Distinguishing attributes
Lean Agile
production production
Typical products Commodities Fashion goods
Marketplace demand Predictable Volatile
Product variety Low High
Product life cycle Long Short
Profit margin Low High

Dominant costs Physical costs Marketability costs
Stock out penalties Long-term contractual Immediate and volatile
Purchasing policy Buy materials Assign capacity
Forecasting mechanism Algorithmic Consultative

Lean V/s Agile
LEAN PRODUCTION AGILE MANUFACTURING
 Minimize waste  Enrich the customer


 
 Perfect first-time quality  Cooperate to enhance competitiveness


  Organize to master change

 Flexible production lines 
 
  Leverage the impact of people and

 Continuous improvement information
Lean V/s Agile
LEAN PRODUCTION AGILE MANUFACTURING
Enhancement of mass production

 Break with mass production; emphasis

on mass customization.
Flexible production for product variety

 Greater flexibility for customized

products

Focus on factory operations

 Scope is enterprise wide

 
Emphasis on supplier management

 Formation of virtual enterprises

 
Emphasis on efficient use of resources

 Emphasis on thriving in environment

 marked by continuous unpredictable

 change
Relies on smooth production schedule

  Acknowledges and attempts to be responsive
to change.
What is Agile?
Information flow through Product is upgraded and

the organization is smooth reconfigured, rather than be
and uninterrupted allowing replaced.
the integration of
functional areas.
Integrates design,
Increasingly leverage engineering,
the intellectual power
of the employees
Agile manufacturing with
marketing and sales in
as opposed to their such a way that the
muscle power products are customized
to the exact needs of the
consumer
Greatly reduce the levels Goal–Produce products which

of management, thus completely satisfy consumer
facilitating the decision- needs and wants
making process
Key attributes of agile
1 2 3
Customer value Flexibility to Organisational
focus (solutions adapt to knowledge,
not products) fundamental including ability
market changes to adapt IT
systems to
support new
processes
Types of Relationship
1 2
Internal: Between co-workers and External: Between the company and

between supervisors and external suppliers, customers, and
subordinates partners
(1)make the work organization (1)establish interactive, proactive
adaptive relationships with customers
(2)Provide cross-functional (2)Provide rapid identification and
training certification of supplier
(3) Encourage rapid partnership (3)Encourage rapid partnership
formation formation for mutual
(4) provide effective electronic commercial advantage
communications capability
Marketing
Characteristics of Agile firms
Leverage the
Cooperate to
Organize Impact of Enrich the
Enhance
to Master People and Customer
Competitivenes
Change Information s
The Pareto Curve Approach

Agile Manufacturing

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LOGO

Mass Lean Agile

Ford , Toyota , USA / Europe

Agile manufacturing is a method for manufacturing which

Craft Mass JIT Agile

Craft Mass JIT Agile

Sensitivity to customer High Low Medium

NIKE – Shoe Industry

BMW-MINI ROOF DESIGN

BMW-MINI ROOF DESIGN

BMW-MINI ROOF DESIGN

FREDDY & MA PURSES

ELITE VINTNERS – Wine Industry

Scanning and processing

Analyze Proposed Systems Prototype Panels

Agility in Supplier Relations

Supplier base be rationalised

Limited number of strategic

High level of shared information

Multiple collaborative working

Supplier Side Agility – Mobile OS

Agile Network – Nokia (India)

The aim of the agile supply chain is to carry

Increases the efficiency of the supply chain by

Reduces the risk of -

Reduces total cost

Agility in Distribution Networks

Fewer stock-keeping variants

Mass Customisation in true terms

DELL – User Interface

Select Your Own Trim

Select Your Vehicle Options

Make to stock Make to order

Mass, repetitive Product

Make to forecast Stock Make to order

Product variety Low High

Product life cycle Long Short

Profit margin Low High

Stock out penalties Long-term contractual Immediate and volatile

Purchasing policy Buy materials Assign capacity

Forecasting mechanism Algorithmic Consultative

 Minimize waste  Enrich the customer

 Perfect first-time quality  Cooperate to enhance competitiveness

  Organize to master change

  Leverage the impact of people and

Enhancement of mass production

Flexible production for product variety

Focus on factory operations

Emphasis on supplier management

Emphasis on efficient use of resources

 marked by continuous unpredictable

Relies on smooth production schedule

Information flow through Product is upgraded and

Greatly reduce the levels Goal–Produce products which

Internal: Between co-workers and External: Between the company and

Characteristics of Agile firms

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