lean manufacturing line demonstration this short powerpoint presentation is designed to give the...

Lean Manufacturing Line Demonstration

This short PowerPoint presentation is designed to give the reader an example of how a Lean/Pull system operates. It demonstrates how a process, (i.e final assembly) is divided into individual workstations equal to a TAKT time. This causes the work in a process to be balanced where all workstations complete the standard work at the same time. TAKT time is a statement of rate calculated as the available time per day divided by the designed volume of the process. Even though standard work time may vary from process to process and product to product, one complete unit is finished each TAKT time.

Because all processes are completed simultaneously, no work in process inventory is accumulated between processes. Customer lead time is the sum of the TAKT times through the critical path processes of the Lean line. Priority changes in customer demand are easily facilitated by rearranging the sequence of demand introduced to the lean line on any given day.

Customers rarely order the same volume of demand every day. Matching labor resources to customer demand each day avoids building unsold finished goods inventory. Operator job satisfaction is enhanced by being allowed to be flexible to do different work every day as

needed.

Please enjoy viewing this presentation. Review as often as necessary to re-enforce your knowledge of how a Lean/Pull system works. Consider how a Lean manufacturing operating system delivers the critical differentials in price, delivery, and quality to give you the leverage you need to capture market share from your competitors.

Please contact Dennis Hobbs at Mfg Matters if you have questions about this presentation or any other questions you may have about a Lean business transformation.

Sequenced Build – First in – First Out at TAKT Rate Mixed Model Production

Two Bin Material Kanban System

No Work-Center Schedule – Respond to TAKT Signal

Build-to-Order Production – No WIP Build up

Production Sequencing to Match Demand Priority

Output Rate Variation Based On Daily Demand

Flexible EmployeesTakt 1 Takt 2 Takt 3 Takt 4 Takt 5

X

S/OS/OS/OSALESORDER

What To Look For

Empty IPKProduct

75% completeProduct

50% completeProduct

25% complete

WS 1 WS 2 WS3 WS4

Empty Workstation

WS 1 WS 2 WS3 WS4

Primary Bin

Secondary Bin

WS 1 WS 2 WS3 WS4

Is the signal to pullthis unit into

this Workstation

This emptyIPK

WS 1 WS 2 WS3 WS4

Causing this IPKto be empty

Then, this unitis pulled

WS 1 WS 2 WS3 WS4

And materialsare consumed

WS 1 WS 2 WS3 WS4

WS 1 WS 2 WS3 WS4

Product100% complete

WS 1 WS 2 WS3 WS4

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

S/OS/O

S/OSALESORDER

WS 1 WS 2 WS3 WS4

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

S/OS/O

S/O

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

S/O

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

S/O

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

S/O

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/OS/O

Notice that the fourth cycle did not result in a product

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/O

Supermarket

Takt 1 Takt 2 Takt 3 Takt 4 Takt 5

WS 1 WS 2 WS3 WS4

S/O

Supermarket

Sequenced Build – First in – First Out at TAKT Rate Mixed Model Production

Two Bin Material Kanban System

No Work-Center Schedule – Respond to TAKT Signal

Build-to-Order Production – No WIP Build up

Production Sequencing to Match Demand Priority

Output Rate Variation Based On Daily Demand

Flexible EmployeesTakt 1 Takt 2 Takt 3 Takt 4 Takt 5

X

S/OS/OS/OSALESORDER

Did You Observe-?