1 alain prioul flexibility / adaptability. 2 definitions flexibility ability to follow customer...
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Alain Prioul
Flexibility / Adaptability
2
Definitions
Flexibility
Ability to follow customer demandat different Takt
Time
Ability to quickly change from one part number to
another one
Adaptability
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Flexibility
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To reduce WIP + surface + handling + CAPEX
Key condition for high TRS
Key condition for levelling
To reduce lead time
Flexibility : Why ?
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tt
A B C A
tt
QQ 12 h
Stock level AStock level A
Production (batch size 12h)Production (batch size 12h)
Safety stock
Average stockAverage stock
Reduce inventories
6
tt
Average stockSafety stock
tt
QQA B C A B C A B C A B C A B C A B C A B C A B C
Stock level AStock level A
Production (batch size 2h)Production (batch size 2h)
12 h
Reduce inventories
7
Safety stock tt
tt
QQA B C A B C A B C A B C A B C A B C A B C A B C
Stock level AStock level A
Production (batch size 2h)Production (batch size 2h)
12 h
Average stock
Reduce inventories
9
100%
75%
18h
1h
5h
A9h
B9h
5h
P1
C
D
5h
P2
E
F
P3
G
H
P4 P(x)
TRS Increase
10
9h
9h
5h
P1
2h
2h
5h
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
x2 x9
TRS Increase
11
5h
9h
9h
5h
P1 P2 P3 P4 P5 P6
x2
2h
2h
2h2h
2h
2h
2h
2h
2h
2h
2h
x9
TRS Increase
12
9h
9h
5h
2h
2h
P1
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
x2 x9
2h
2h
TRS Increase
13
9h
9h
5h
2h
2h
P1
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
14
9h
9h
5h
2h
2h
P1
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
15
9h
9h
5h
2h
2h
P1
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
16
9h
9h
5h
2h
2h
P1
2h2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
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To reduce WIP + surface + handling + CAPEX
Key condition for high TRS
Key condition for levelling
To reduce lead time
Flexibility : Why ?
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Ideal condition:
Producing all products in parallel at TAKT TIME
(rhythm of customer demand of each part number)
Target : respect the TAKT TIME & full loading of the equipment:
Producing all products in small batches close to TAKT TIME
Levelling
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Customer demand
Production = Large batches
Lead Time reduction
Production = small batches
Lead time
Lead time
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Adaptability :
Flexible Manpower Line
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Flexible Man Power Line : why ?
Work Content change
Customer demand
change
n => n - 1
Takt Time change
Result of Kaizen action
Work content mix
Work ContentNumber of Operators = Takt Time
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Flexible Manpower Line
A line which is designed in such a way
that productivity is the same, whatever is
the number of operators.
Flexible Man Power Line : Definition
Flexible Manpower System
Optimizing labour productivity factory-wide by
moving people from one flexible manpower line to
another.
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Flexible man power line : Layout
U cell Linear (fixe)Unflexible man power line
A
B C
D
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Flexible Manpower Line : Fundamentals
•Linear line configuration or U shape line
•No barrier to operator movement
Line
Operator•Operators work inside the cell
•Operator loaded to takt time
•Operation start and finish at the same point
•One piece product flow by hand
Process
•Standard in process stock Multi-process handling
• Several Standard Work for varying demand
• Flexible working hours
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Flexible Manpower Line : Iso-productivity !
6 operators Demand - 15 % => 5 operators
Demand - 30 % => 4 operators Demand - 50 % => 3 operators
PPH is constant
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- avoid overproduction => less WIP , space , handling
- smooth production => better usage of capacity
- smooth material flow => control lead time
- create standard conditions
- make kaizen possible
Flexible Manpower Line
Flexible Manpower Line
