chapter 8 · 2018. 1. 30. · isolated island layouts linear layouts. 10 under birdcage layout, two...
TRANSCRIPT
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Seoul National University
Professor ILKYEONG MOON
Chapter 8Machine Layout, Multi-Functional Workers, and Job Rotation Help Realize Flexible Workshops
All rights reserved, 2013
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Layout design: the U-turn layout
2
Shojinka: meeting demand through
flexibility8.1
8.2
Attaining Shojinka through multi-
functional workers8.3
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Shojinka (少人化) is attaining flexibility in the
number of workers at a workshop to adapt to
demand changes.
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Shojinka is equivalent to increasing productivity
by the adjustment and rescheduling of human
resources.
Three factors are prerequisite to realize Shojinka:
proper design of machinery layout
a multi-functional worker
continuous evaluation and periodic revisions of the standard
operations routine
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Under the U-turn layout, the entrance and exit of a
line are at the same position.
The U-turn layout has several variations, such as
the concave and circle forms.
The most remarkable advantage is the flexibility
to change the number of workers for the
fluctuation of demand.
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A unit of part can pass into the entrance of the process when
one unit of output leaves through the exit.
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JIT pull production can be achieved.
The quantity of work-in-process can always be
constant.
Unbalanced operations among workers will be
visual.
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There are three major categories of layouts that are
improper for Toyota.
birdcage layouts
isolated island layouts
linear layouts
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Under birdcage layout, two or more stands
containing the same type of machine can be laid
out around the worker.
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The production quantity per worker is high but the
inventory of semi-finished inventory at each
station is also increased.
Production balancing and synchronization among
stations are difficult to achieve.
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Under the isolated island layout, a multi-
functional worker handles different types of
machines in accordance with the sequential order
of processing a part.
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It enables a continuous and smooth flow of
products among different types of machines.
It also ensures a continuous walking route with the
least distance for each worker.
Advantages of isolated island layout
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Workers are separated from one another and
cannot help each other.
Reallocation of operations among workers to
respond to changes in demand is difficult.
Disadvantages of isolated island layout
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Under the linear layout, a multi-functional worker
handles different types of machines that are laid
out in a linear form.
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The linear layout allows products to flow
smoothly and quickly among machines.
It cannot reallocate operations among workers.
It may requires a fractional number of workers,
such as 8.5 workers.
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Toyota combines several U-form lines into one
integrated line.
Can overcome the problem of fractional numbers of workers.
Can reallocate operations among workers.
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Suppose there is a combined process that consists of 6
different lines (A-F).
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According to the monthly demand in January, the cycle
time of this combined process is 1 minute per unit and
8 workers are involved.
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In February, the monthly demand is decreased and
cycle time is increased to 1.2 minutes.
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Each individual U-turn process is a kind of cell, where
either one or two workers are working.
It is easy to increase or decrease the number of workers.
This phenomenon is a key merit of the cellular
manufacturing system.
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The cellular manufacturing system belongs to the
process design based on a product-flow type machine
layout.
It assumes that similar products are flowing through the
process.
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Item or parts with similar physical forms or similar
engineering procedures must be grouped into item
families or part families.
Various machines are identified by the group of
machining operations necessary to process sets of
similar items (or part) families.
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The ability to widen or narrow the range of jobs
performed by each worker is a key ingredient in
achieving Shojinka.
The workers must be multi-functional, i.e., trained to be
a skilled worker for any type of job and at any process.
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Toyota cultivates their workers using a job
rotation system that consists three steps.
1. Each supervisor must
rotate through every job
2. Each worker within the shop
is trained to perform each job
in the shop
3. Schedule the workers
through job rotation several
times each day
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A job rotation plan in Toyota was first implemented at
the Tsutsumi Factory.
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The managers and supervisors must first display
themselves as examples of the multi-functional worker.
The general foremen, foremen, and line chiefs were
rotated among each work’s shop and line in Toyota’s
Tsutsumi Plant.
This job rotation plan was a part of a long-range
planning program.
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For the rotation of each worker, a job-training plan
must be scheduled.
A multi-functional worker rate for each shop must be
formulated (n is the number of workers at the shop).
1number of processes that worker has mastered
total number of prcesses within the shop
n
ii
n
What does the rate equal to 1 mean?
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What is the rate
in this plant?
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When the multi-functional worker rate is high, job
rotation could be made every week, or in many cases
every day.
All workers could be rotated among all processes in
two- or four-hour intervals.
Suppose that 160 mm differential carriers are
assembled by 8 workers within the cycle time of 26
seconds.
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Job rotation in this example is accomplished in
intervals of 2 hours.
A job rotation schedule must be planned for the five
days of the following week.
A fair allocation and the training program for the
newcomer should be considered.
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Workers’ attitudes are refreshed and muscle fatigue can
be prevented.
The feeling of unfairness that veterans must have heavy
work will disappear.
The skills and know-how are dispersed throughout the
shop.
Additional advantages of job rotation
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Each worker feels responsible for all goals of the shop.
At new shops and processes, ideas and suggestions will
increase remarkably.
These benefits can be summarized with respect for
humans.
Additional advantages of job rotation (continued)
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Allows workers to take a rest while still permitting job
rotation.
Importance of the line chief
process
worker
line chief
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Suppose that one unit has been produced in a 2-minute
cycle time by only one worker.
Assume that the cycle time was reduced to 1.5 minutes
due to increased demand.
An additional worker should be introduced and the two
workers totally have 1 minute of idle time in each cycle.