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Mastering Flow with High Product Mixes &
Unpredictable Demand
Abe Dabdoub, Senior Faculty Member
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Abe Dabdoub, EEng, MBASenior Faculty Member
Clients• United Technologies
Corporation • FMC Technologies• Senior Aerospace• Sikorsky• Aetna
Credentials• Over 25 years of
progressive operational excellence experience in health insurance, oil & gas, aerospace, automotive and electronics industries.
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FAQ
• Registrants will receive a copy of these slides, along with a video playback link, in an email tomorrow
• We strongly encourage questions from the audience at anytime, please use the questions window
• Questions will be answered at the end of this presentation
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Continuous Improvement
Companies have done continuous improvement activities for years…
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Continuous Improvement
Pareto
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Continuous Improvement
Impact
Effort
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Continuous Improvement
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The Lean Journey
SustainImprove
SustainImprove
SustainImprove
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Operational Excellence
Mature lean company
Time in Years
Leve
l of i
mpr
ovem
ent
1 5 10
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Operational Excellence
Operational Excellence
Time in Years
Leve
l of i
mpr
ovem
ent
1 5 10
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The ‘Jump’ to Operational Excellence
Time in Years
Leve
l of i
mpr
ovem
ent
1 5 10
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Operational Excellence
“When each and every employee can see the flow of value to the customer, and fix that flow before it breaks down.” SM
Kevin J. Duggan
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Mixed Model Production
Fixed Schedule (Mixed Model)Automotive Model Dealers deal with
True Customer Demand
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The Eight Steps to Achieve Operational Excellence
1. Design a lean flow using lean guidelines.2. Implement a lean flow.3. Make the lean flow visual.4. Create standard work for the lean flow.5. Make abnormal flow visual.6. Create standard work for the abnormal flow.7. Teach employees to maintain and improve the flow to
the customer.8. Free management to work on offense.
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The Eight Steps to Achieve Operational Excellence
1. Design a lean flow using lean guidelines.2. Implement a lean flow.3. Make the lean flow visual.4. Create standard work for the lean flow.5. Make abnormal flow visual.6. Create standard work for the abnormal flow.7. Teach employees to maintain and improve the flow to
the customer.8. Free management to work on offense.
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How Did This Happen?
Current State Map
Future State Map
Kaizen
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Improving Operations
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The Correct Process for OpEx
Current State Map
Future State Map
Apply Guidelines
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Eight Guidelines for End-to-End Value Stream Design
XOXO
Eight VS Guidelines
Form Assembly Test Ship
FIFOFIFO
2 days 1 day 1 day 1 day 5 days
2 sec 20 min 10 min 15 min 45 min
DailyWeekly
CustomerSupplier
Production Control6 Week
ForecastWeekly Orders
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Ten Guidelines for the Mixed Model Pacemaker
Ten Guidelines for the Mixed Model Pacemaker
Ten MM Guidelines1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Daily
Pacemaker
CustomerSupplier
Production Control6 Week
ForecastWeekly Orders
XOXO
Form Assembly Test Ship
FIFOFIFO
2 days 1 day 1 day 1 day 5 days
2 sec 20 min 10 min 15 min 45 min
Weekly
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Six Guidelines for Shared Resources Flow
Shared Resource Shared Resource
Form Test
XOXO
Assembly Ship
FIFOFIFO
2 days 1 day 1 day 1 day 5 days2 sec 20 min 10 min 15 min 45 min
DailyWeekly
CustomerSupplier
Production Control6 Week
ForecastWeekly Orders
Six SRF Guidelines
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Nine Guidelines for Office FlowNine Guidelines for Office Flow
Nine Office Guidelines
1.
2.
3.
4.
5.
6.
7.
8.
9.
Customers Customers
Sales Database
email
Design Pkg.Create
File
Log File
P/T=15 min.1 CSR
Request Form
FIFO
4 Hrs.
4 Estimates per Day
L/TP/T
1.5 Days + 187 min
187 min.17 Min. 170 Min.
Max = 1.5 days
P/T=170 min.PC/T=55 min.
Op = 3
Takt = 60 min.
Post Office
0 – 1.5 days
email
Estimating Cell
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Ten Guidelines for the Mixed Model Pacemaker
Ten Guidelines for the Mixed Model Pacemaker
Ten MM Guidelines1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Daily
Pacemaker
CustomerSupplier
Production Control6 Week
ForecastWeekly Orders
XOXO
Form Assembly Test Ship
FIFOFIFO
2 days 1 day 1 day 1 day 5 days
2 sec 20 min 10 min 15 min 45 min
Weekly
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Mix of Products Flow through the Same Value Stream
How will we run all these products through the same value stream when demand
changes each day?
Stamp
Pistons: 45-80 unitsBrackets: 50-90 unitsArms: 25-75 units
Collars: 30-55 unitsDiverters: 35-60 unitsDetectors: 20-40 units
Lifters: 55-75 unitsLevers: 60-95 unitsCranks: 40-70 units
Paint Assemble ShipFIFO
max 50
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Sequencing Box
123456789
A
A
A
B
B
B
C
D
E
VSM Illustration
Upstreammax. 50 piecesDownstream
ProcessProcess
Supermarket
X O X O
1 2 3 4
FIFO Lane
VSM Shared Res PS
Assembly
Supermarket
FIFO
* Changeover Time* Run Time / Container* Transport Time* Wait Time
How long before we get the first container back into the supermarket? Into Assembly?
Supply
Min Pull Signal
?
VSM Product Flow
max. 50 pieces
FIFO Lane
Ship
Assemble
Paint
Stamp
Collars...30-55 unitsDiverters...35-60 unitsDetectors...20-40 units
Pistons...45-80 unitsBrackets...50-90 unitsArms...25-75 units
Lifters...55-75 unitsLevers...60-95 unitsCranks...40-70 units
Buffer Cones
ORIGINAL BUFFER SETUP
Remove the cone when you use the box.
AFTER TWO WEEKS
You do not need any space where cones remain.
Sequencing Box
123456789
A
A
A
B
B
B
C
D
E
VSM Illustration
Upstreammax. 50 piecesDownstream
ProcessProcess
Supermarket
X O X O
1 2 3 4
FIFO Lane
VSM Shared Res PS
Assembly
Supermarket
FIFO
* Changeover Time* Run Time / Container* Transport Time* Wait Time
How long before we get the first container back into the supermarket? Into Assembly?
Supply
Min Pull Signal
?
VSM Product Flow
max. 50 pieces
FIFO Lane
Ship
Assemble
Paint
Stamp
Collars...30-55 unitsDiverters...35-60 unitsDetectors...20-40 units
Pistons...45-80 unitsBrackets...50-90 unitsArms...25-75 units
Lifters...55-75 unitsLevers...60-95 unitsCranks...40-70 units
Buffer Cones
ORIGINAL BUFFER SETUP
Remove the cone when you use the box.
AFTER TWO WEEKS
You do not need any space where cones remain.
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Which Type of Value Stream is this?
Degree of customization required
Numberof
Products
Discrete manufacturer
1
Discrete manufacturerHigh mix
2Job shop
Very high mixHigh customization
3
Low mixHigh customization
4
Make to Order Mfg.Discrete Mfg.
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Welcome to EMC Supply Co.
• In today’s class we will visit the Electro-Motion Control (EMC) Supply Co.
• EMC Supply Co. builds a wide variety of products for the motion control and electronics industries. They supply distributors and end users. They also build custom products to order.
• The management at EMC Supply Co. have stated that want to achieve self-healing value stream flow in their high mix environment.
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Mixed Model Value Streams
To produce a variety or mix of products or product variations through the same value stream…
AT THE PULL OF THE CUSTOMER.
Stamp
Pistons: 45-80 unitsBrackets: 50-90 unitsArms: 25-75 units
Collars: 30-55 unitsDiverters: 35-60 unitsDetectors: 20-40 units
Lifters: 55-75 unitsLevers: 60-95 unitsCranks: 40-70 units
Paint Assemble ShipFIFO
max 50
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Sequencing Box
123456789
A
A
A
B
B
B
C
D
E
VSM Illustration
Upstreammax. 50 piecesDownstream
ProcessProcess
Supermarket
X O X O
1 2 3 4
FIFO Lane
VSM Shared Res PS
Assembly
Supermarket
FIFO
* Changeover Time* Run Time / Container* Transport Time* Wait Time
How long before we get the first container back into the supermarket? Into Assembly?
Supply
Min Pull Signal
?
VSM Product Flow
max. 50 pieces
FIFO Lane
Ship
Assemble
Paint
Stamp
Collars...30-55 unitsDiverters...35-60 unitsDetectors...20-40 units
Pistons...45-80 unitsBrackets...50-90 unitsArms...25-75 units
Lifters...55-75 unitsLevers...60-95 unitsCranks...40-70 units
Buffer Cones
ORIGINAL BUFFER SETUP
Remove the cone when you use the box.
AFTER TWO WEEKS
You do not need any space where cones remain.
Sequencing Box
123456789
A
A
A
B
B
B
C
D
E
VSM Illustration
Upstreammax. 50 piecesDownstream
ProcessProcess
Supermarket
X O X O
1 2 3 4
FIFO Lane
VSM Shared Res PS
Assembly
Supermarket
FIFO
* Changeover Time* Run Time / Container* Transport Time* Wait Time
How long before we get the first container back into the supermarket? Into Assembly?
Supply
Min Pull Signal
?
VSM Product Flow
max. 50 pieces
FIFO Lane
Ship
Assemble
Paint
Stamp
Collars...30-55 unitsDiverters...35-60 unitsDetectors...20-40 units
Pistons...45-80 unitsBrackets...50-90 unitsArms...25-75 units
Lifters...55-75 unitsLevers...60-95 unitsCranks...40-70 units
Buffer Cones
ORIGINAL BUFFER SETUP
Remove the cone when you use the box.
AFTER TWO WEEKS
You do not need any space where cones remain.
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Mixed Model Value Streams
EMC Product Family
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Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10.How do we deal with changes in customer demand?
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Product Family Matrix
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Product Family Matrix
P/N Name Inje
ctio
n M
oldi
ng
Stam
p
Debu
rr
Han
d De
burr
Pain
t
Wel
ding
Mec
hani
cal A
ssy
Elec
tric
al A
ssy
Fina
l Ass
y
Conf
igur
e &
Tes
t
Ship
12834 XS2 Servo Motor X X X X X X X18392 Sensor-Activated Arm X X X A X X X X X X X19283 Photoelectric Detector X X X X19299 Ionization Detector X X X X X21000 Laser-Activated Arm X X X X X X X X X X21032 Manual Servo Motor X X X X X X X21042 Manual Servo Motor II X X X X X X X22020 Manually-Activated Arm X X X A X X X X X X X23756 Fiber Optic Visual Sensor X X X X X X24783 XS3 Servo Motor X X X X X X X25030 Radon Detecter X X X X28121 Bar Code Divertor Piston X X X A X X X X X X X30000 Bar Code Diverter Arm X X X A X X X X X X X31000 Sensor-Activated Piston X X X A X X X X X X X31666 Laser Diverter X X X X X X X X X X32220 XS4 Servo Motor X X X X X X X34556 Carbon Monoxide Detector X X X X X35599 Auto Servo Motor X X X X X X X38200 Laser-Activated Piston X X X X X X X X X X42005 Manually-Activated Piston X X X A X X X X X X X45890 Motion Detector X X X X
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(1) X Map
P/NNameInjection MoldingStampDeburrHand DeburrPaintWeldingMechanical AssyElectrical AssyFinal AssyConfigure & TestShip
12834XS2 Servo MotorXXXXXXX
18392Sensor-Activated ArmXXXAXXXXXXX
19283Photoelectric DetectorXXXX
19299Ionization DetectorXXXXX
21000Laser-Activated ArmXXXXXXXXXX
21032Manual Servo MotorXXXXXXX
21042Manual Servo Motor IIXXXXXXX
22020Manually-Activated ArmXXXAXXXXXXX
23756Fiber Optic Visual SensorXXXXXX
24783XS3 Servo MotorXXXXXXX
25030Radon DetecterXXXX
28121Bar Code Divertor PistonXXXAXXXXXXX
30000Bar Code Diverter ArmXXXAXXXXXXX
31000Sensor-Activated PistonXXXAXXXXXXX
31666Laser DiverterXXXXXXXXXX
32220XS4 Servo MotorXXXXXXX
34556Carbon Monoxide DetectorXXXXX
35599Auto Servo MotorXXXXXXX
38200Laser-Activated PistonXXXXXXXXXX
42005Manually-Activated PistonXXXAXXXXXXX
45890Motion DetectorXXXX
(2) Sorted X Map
ACME Supply Company
SORTED X MAP
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipFAMILY
18392LED-Activated ArmXXXXXXAXXXXA
21000Laser-Activated ArmXXXXXXXXXXA
22020Manually-Activated ArmXXXXXXAXXXXA
28121Bar Code Divertor PistonXXXXXXAXXXXA
30000Bar Code Divertor ArmXXXXXXAXXXXA
31000LED-Activated PistonXXXXXXAXXXXA
31666Super Laser DivertorXXXXXXXXXXA
38200Laser-Activated PistonXXXXXXXXXXA
42005Manually-Activated PistonXXXXXXAXXXXA
12834XS2 Servo MotorXXXXXXB
21032Manual Servo MotorXXXXXXB
21042Manual Servo Motor IIXXXXXXB
24783XS3 Servo MotorXXXXXXB
32220XS4 Servo MotorXXXXXXB
35599Auto Servo MotorXXXXXXXB
19283Photoelectric DetectorXXXXC
19299Ionization DetectorXXXXXC
23756Fiber Optic Visual SensorXXXXXXC
25030Radon DetectorXXXXC
34556Carbon Monoxide DetectorXXXXXC
45890Motion DetectorXXXXC
(3) Content Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL
18392LED-Activated Arm351459014010A3060130180X691
21000Laser-Activated Arm30130601603060100300X771
22020Manually-Activated Arm4514012017520A456090220X771
28121Bar Code Divertor Piston301359024015A306090300X861
30000Bar Code Divertor Arm5514510018030A6060105180X756
31000LED-Activated Piston601406512510A306090240X691
31666Super Laser Divertor6014024030030602404801451
38200Laser-Activated Piston601351201803060125480X1091
42005Manually-Activated Piston401358014510A3060100240X711
Work Content > 30%
(4) Remove Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL
18392LED-Activated Arm351459014010A3060130180X691
21000Laser-Activated Arm30130601603060100300X771
22020Manually-Activated Arm4514012017520A456090220X771
28121Bar Code Divertor Piston301359024015A306090300X861
30000Bar Code Divertor Arm5514510018030A6060105180X756
31000LED-Activated Piston601406512510A306090240X691
31666Super Laser Divertor6014024030030602404801451
38200Laser-Activated Piston601351201803060125480X1091
42005Manually-Activated Piston401358014510A3060100240X711
Move to another product family
(5) Final Matrix
ACME Supply Company
FINAL PRODUCT FAMILY A MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL
18392LED-Activated Arm351459014010A3060130180X691
21000Laser-Activated Arm30130601603060100300X771
22020Manually-Activated Arm4514012017520A456090220X771
28121Bar Code Divertor Piston301359024015A306090300X861
30000Bar Code Divertor Arm5514510018030A6060105180X756
31000LED-Activated Piston601406512510A306090240X691
38200Laser-Activated Piston601351201803060125480X1091
42005Manually-Activated Piston401358014510A3060100240X711
Sequence in, limit mix
(6) Final Matrix Cell
ACME Supply Company
DEMAND MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTALDEMAND
18392LED-Activated Arm351459014010A3060130180X69165
21000Laser-Activated Arm30130601603060100300X77185
22020Manually-Activated Arm4514012017520A456090220X77135
28121Bar Code Divertor Piston301359024015A306090300X86170
30000Bar Code Divertor Arm5514510018030A6060105180X75650
31000LED-Activated Piston601406512510A306090240X69155
38200Laser-Activated Piston601351201803060125480X109120
42005Manually-Activated Piston401358014510A3060100240X71125
(7) ACME Process Map
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXXXXXXX
Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburHand DeburPaintFinal AssemblyConfigure & Test
DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
LED-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065065603600750065130845065180117006911265ABC
Laser-Activated Arm210008995%360030627885270012785853003028508560510085160136008530255085603600870085100850085300255007711385ABC
Manually-Activated Arm220203795%360045525435270012735353004017003512042003517561253520700350356036005700359031503522077007711335ABC
Bar Code Divertor Piston281217495%36003058057027001277070300352750709063007024016800701510507007060360078007090630070300210008611470SS
Bar Code Divertor Arm300005395%36005564885027001275050300452550501005000501809000503015005005060360066005010552505018090007561350SS
LED-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505505560360069005590495055240132006911255SS
Laser-Activated Piston382002195%36006048602027001272020300351000201202400201803600203060020603600480020125250020480960010911820SS
Manually-Activated Piston420052695%360040465025270012725253003511752580200025145362525102502502560360051002510025002524060007111225SS
Custom Orders (10%)XXX4795%3600556199452700127454530030165045954275451607200453013504504560360063004510547254522099007561345Custom
TOTAL TIME5258624750Wct=37.111111111119400Wct=8638700Wct=168.7222222222759256050315059400Wct=102.944444444446325Wct=252.44444444441136007099118450
TOTAL QUANTITY473450450450450345450450450450
W=5400047808547204860054000540005400054000486005400054000
PROCESS PACE TIME101.2121.6108.0120.0120.0156.5120.0108.0120.0120.0
RESOURCES1.100.450.400.721.410.110.061.220.862.10
REVISED:6/21/01BAM
&LRev B&CPrepared By: BAM -- Duggan && Associates Inc.&R&D
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:100T press83% uptime95% Yield
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:95% uptime 2 shifts 8 hours/shift
Brian A. Moffitt:150T press95% uptime
Brian A. Moffitt:83% Uptime2 shifts8 hours/shift
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:%Uptime = 90%
Brian A. Moffitt:90% uptime
Brian A. Moffitt:30-45 range
Summary
(8) Summary
DeburPaintHand Debur
0.111.220.06
StampWeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
0.450.400.721.410.862.10
Injection Mold
1.10GO TO PROCESS MAP
TOTAL RESOURCES:8.43
&LPerkin Elmer Instruments&CProcess Map Summary Sheet&RLean GC
&LPrepared By: BAM -- Duggan && Associates Inc.&R&D
GO TO PROCESS MAP
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Three Potential Families
P/N Name Hand
Deb
ur
Pain
t
Wel
ding
Mech
anic
al A
ssy
Elec
trica
l Ass
y
Fina
l Ass
y
Conf
igur
e &
Test
Ship
FAMI
LY
18392 Sensor-Activated Arm A X X X X X X X A21000 Laser-Activated Arm X X X X X X X X A22020 Manually-Activated Arm A X X X X X X X A28121 Bar Code Divertor Piston A X X X X X X X A30000 Bar Code Divertor Arm A X X X X X X X A31000 Sensor-Activated Piston A X X X X X X X A31666 Laser Divertor X X X X X X X X A38200 Laser-Activated Piston X X X X X X X X A42005 Manually-Activated Piston A X X X X X X X A12834 XS2 Servo Motor X X X X B21032 Manual Servo Motor X X X X B21042 Manual Servo Motor II X X X X B24783 XS3 Servo Motor X X X X B32220 XS4 Servo Motor X X X X B35599 Auto Servo Motor X X X X B19283 Photoelectric Detector X X X X C19299 Ionization Detector X X X X X C23756 Fiber Optic Visual Sensor X X X X X X C25030 Radon Detector X X X X C34556 Carbon Monoxide Detector X X X X X C45890 Motion Detector X X X X C
A
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A Sensor-Activated Arm 30 60 45 90 140 130 110 X 605
B Laser-Activated Arm 30 60 30 60 140 100 110 X 530
C Manually-Activated Arm 45 60 40 120 150 90 100 X 605
D Bar Code Diverter Piston 30 60 35 90 180 140 110 X 645
E Bar Code Diverter Arm 60 60 45 100 180 105 105 X 655
F Sensor-Activated Piston 30 60 40 85 105 90 90 X 500
G Laser-Activated Piston 30 60 35 150 130 140 200 X 745
H Manually-Activated Piston 30 60 35 80 145 100 100 X 550
I Laser Diverter 30 60 40 240 300 240 80 X 990
X Custom Orders 30 60 30 120 160 105 110 X 615
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(1) X Map
ACME Supply Company
X MAP
P/NNameInjection MoldingStampDeburHand DeburWeldingPaintMechanical AssyElectrical AssyFinal AssyConfigure & TestShip
12834XS2 Servo MotorXXXXXX
18392Sensor-Activated ArmXXXAXXXXXXX
19283Photoelectric DetectorXXXX
19299Ionization DetectorXXXXX
21000Laser-Activated ArmXXXAXXXXXXX
21032Manual Servo MotorXXXXXX
21042Manual Servo Motor IIXXXXXX
22020Manually-Activated ArmXXXAXXXXXXX
23756Fiber Optic Visual SensorXXXXXX
24783XS3 Servo MotorXXXXXX
25030Radon DetectorXXXX
28121Bar Code Divertor PistonXXXAXXXXXXX
30000Bar Code Divertor ArmXXXAXXXXXXX
31000Sensor-Activated PistonXXXAXXXXXXX
31666Laser DivertorXXXAXXXXXXX
32220XS4 Servo MotorXXXXXX
34556Carbon Monoxide DetectorXXXXX
35599Auto Servo MotorXXXXXXX
38200Laser-Activated PistonXXXAXXXXXXX
42005Manually-Activated PistonXXXAXXXXXXX
45890Motion DetectorXXXX
(2) Sorted X Map
ACME Supply Company
SORTED X MAP
P/NNameInjection MoldingStampDeburWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipFAMILY
18392Sensor-Activated ArmXXXXXAXXXXXA
21000Laser-Activated ArmXXXXXAXXXXXA
22020Manually-Activated ArmXXXXXAXXXXXA
28121Bar Code Divertor PistonXXXXXAXXXXXA
30000Bar Code Divertor ArmXXXXXAXXXXXA
31000Sensor-Activated PistonXXXXXAXXXXXA
31666Laser DivertorXXXXXAXXXXXA
38200Laser-Activated PistonXXXXXAXXXXXA
42005Manually-Activated PistonXXXXXAXXXXXA
12834XS2 Servo MotorXXXXXXB
21032Manual Servo MotorXXXXXXB
21042Manual Servo Motor IIXXXXXXB
24783XS3 Servo MotorXXXXXXB
32220XS4 Servo MotorXXXXXXB
35599Auto Servo MotorXXXXXXXB
19283Photoelectric DetectorXXXXC
19299Ionization DetectorXXXXXC
23756Fiber Optic Visual SensorXXXXXXC
25030Radon DetectorXXXXC
34556Carbon Monoxide DetectorXXXXXC
45890Motion DetectorXXXXC
(3) Content Matrix
ACME Supply Company
NameHand DeburPaintWeldingMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
ASensor-Activated Arm30604590140130110X605
BLaser-Activated Arm30603060140100110X530
CManually-Activated Arm45604012015090100X605
DBar Code Diverter Piston30603590180140110X645
EBar Code Diverter Arm606045100180105105X655
FSensor-Activated Piston306040851059090X500
GLaser-Activated Piston306035150130140200X745
HManually-Activated Piston30603580145100100X550
ILaser Diverter30604024030024080X990
XCustom Orders306030120160105110X615
(4) Remove Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
18392Sensor-Activated Arm4560309014013025X520
21000Laser-Activated Arm3060306014010045X465
22020Manually-Activated Arm4060451201759060X590
28121Bar Code Divertor Piston356030902409030X575
30000Bar Code Divertor Arm45606010018010530X580
31000Sensor-Activated Piston406030651259045X455
31666Laser Divertor40603024030024030X940
38200Laser-Activated Piston356030120180125110X660
42005Manually-Activated Piston3560308014510045X495
Move to another product family
(5) Final Matrix
ACME Supply Company
FINAL MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
18392Sensor-Activated Arm4560309014013025X520
21000Laser-Activated Arm3060306014010045X465
22020Manually-Activated Arm4060451201759060X590
28121Bar Code Divertor Piston356030902409030X575
30000Bar Code Divertor Arm45606010018010530X580
31000Sensor-Activated Piston406030651259045X455
38200Laser-Activated Piston356030120180125110X660
42005Manually-Activated Piston3560308014510045X495
(6) Final Matrix Cell
ACME Supply Company
FINAL MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTALCell TimesCell Cycle TimeDemand
18392Sensor-Activated Arm4560309014013025X520430
21000Laser-Activated Arm3060306014010045X465375
22020Manually-Activated Arm4060451201759060X590485
28121Bar Code Divertor Piston356030902409030X575485
30000Bar Code Divertor Arm45606010018010530X580460
31000Sensor-Activated Piston406030651259045X455365
38200Laser-Activated Piston356030120180125110X660570
42005Manually-Activated Piston3560308014510045X495
485
total work
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXX
WeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
DescriptionP/NQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
Sensor-Activated Arm18392653004532256590585065140910065130845065180117005851065ABC
Laser-Activated Arm210008530030285085605100851601360085100850085240204005901085ABC
Manually-Activated Arm2202035300401700351204200351756125359031503522077006451135ABC
Bar Code Divertor Piston28121703003527507090630070240168007090630070200140006551170SS
Bar Code Divertor Arm30000503004525505010050005018090005010552505018090006101050SS
Sensor-Activated Piston310005530040250055653575551256875559049505524013200560955SS
Laser-Activated Piston38200203003510002012024002018036002012525002048096009401620SS
Manually-Activated Piston4200525300351175258020002514536252510025002524060006001025SS
Custom Orders (10%)XXX45300301650459542754516072004510547254522099006101045Custom
TOTAL TIMEWct=37.111111111119400Wct=8638700Wct=168.722222222275925Wct=102.944444444446325Wct=225.555555555610150062010450
TOTAL QUANTITY450450450450450
W=540004860054000540005400054000
PROCESS PACE TIME108.0120.0120.0120.0120.0
RESOURCES0.400.721.410.861.88
REVISED:6/21/01
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:30-45 range
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:%Uptime = 90%
Summary
(7) ACME Process Map
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXXXXXX
Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburPaintFinal AssemblyConfigure & Test
DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
Sensor-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065603600750065130845065180117006911265ABC
Laser-Activated Arm210008995%360030627885270012785853003028508560510085160136008530255085603600870085100850085240204007111285ABC
Manually-Activated Arm220203795%360045525435270012735353004017003512042003517561253520700356036005700359031503522077007711335ABC
Bar Code Divertor Piston281217495%36003058057027001277070300352750709063007024016800701510507060360078007090630070200140007611370SS
Bar Code Divertor Arm300005395%36005564885027001275050300452550501005000501809000503015005060360066005010552505018090007561350SS
Sensor-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505560360069005590495055240132006911255SS
Laser-Activated Piston382002195%36006048602027001272020300351000201202400201803600201530020603600480020125250020480960010761820SS
Manually-Activated Piston420052695%360040465025270012725253003511752580200025145362525102502560360051002510025002524060007111225SS
Custom Orders (10%)XXX4795%3600556199452700127454530030165045954275451607200453013504560360063004510547254522099007561345Custom
TOTAL TIME5258624750Wct=37.111111111119400Wct=8638700Wct=168.722222222275925890059400Wct=102.944444444446325Wct=225.55555555561015006924115450
TOTAL QUANTITY473450450450450450450450450
W=54000478085472048600540005400054000486005400054000
PROCESS PACE TIME101.2121.6108.0120.0120.0120.0108.0120.0120.0
RESOURCES1.100.450.400.721.410.161.220.861.88
REVISED:6/21/01BAM
&LRev B&CPrepared By: BAM -- Duggan && Associates Inc.&R&D
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:100T press83% uptime95% Yield
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:95% uptime 2 shifts 8 hours/shift
Brian A. Moffitt:150T press95% uptime
Brian A. Moffitt:83% Uptime2 shifts8 hours/shift
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:%Uptime = 90%
Brian A. Moffitt:90% uptime
Brian A. Moffitt:30-45 range
Summary
(8) Summary
DeburPaint
0.161.22
StampWeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
0.450.400.721.410.861.88
Injection Mold
1.10GO TO PROCESS MAP
TOTAL RESOURCES:8.20
&LPerkin Elmer Instruments&CProcess Map Summary Sheet&RLean GC
&LPrepared By: BAM -- Duggan && Associates Inc.&R&D
GO TO PROCESS MAP
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© 2018 Institute for Operational Excellence. All Right Reserved.
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A Sensor-Activated Arm 30 60 45 90 140 130 110 X 605
B Laser-Activated Arm 30 60 30 60 140 100 110 X 530
C Manually-Activated Arm 45 60 40 120 150 90 100 X 605
D Bar Code Diverter Piston 30 60 35 90 180 140 110 X 645
E Bar Code Diverter Arm 60 60 45 100 180 105 105 X 655
F Sensor-Activated Piston 30 60 40 85 105 90 90 X 500
G Laser-Activated Piston 30 60 35 150 130 140 200 X 745
H Manually-Activated Piston 30 60 35 80 145 100 100 X 550
I Laser Diverter 30 60 40 240 300 240 80 X 990
X Custom Orders 30 60 30 120 160 105 110 X 615
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(1) X Map
ACME Supply Company
X MAP
P/NNameInjection MoldingStampDeburHand DeburWeldingPaintMechanical AssyElectrical AssyFinal AssyConfigure & TestShip
12834XS2 Servo MotorXXXXXX
18392Sensor-Activated ArmXXXAXXXXXXX
19283Photoelectric DetectorXXXX
19299Ionization DetectorXXXXX
21000Laser-Activated ArmXXXAXXXXXXX
21032Manual Servo MotorXXXXXX
21042Manual Servo Motor IIXXXXXX
22020Manually-Activated ArmXXXAXXXXXXX
23756Fiber Optic Visual SensorXXXXXX
24783XS3 Servo MotorXXXXXX
25030Radon DetectorXXXX
28121Bar Code Divertor PistonXXXAXXXXXXX
30000Bar Code Divertor ArmXXXAXXXXXXX
31000Sensor-Activated PistonXXXAXXXXXXX
31666Laser DivertorXXXAXXXXXXX
32220XS4 Servo MotorXXXXXX
34556Carbon Monoxide DetectorXXXXX
35599Auto Servo MotorXXXXXXX
38200Laser-Activated PistonXXXAXXXXXXX
42005Manually-Activated PistonXXXAXXXXXXX
45890Motion DetectorXXXX
(2) Sorted X Map
ACME Supply Company
SORTED X MAP
P/NNameInjection MoldingStampDeburWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipFAMILY
18392Sensor-Activated ArmXXXXXAXXXXXA
21000Laser-Activated ArmXXXXXAXXXXXA
22020Manually-Activated ArmXXXXXAXXXXXA
28121Bar Code Divertor PistonXXXXXAXXXXXA
30000Bar Code Divertor ArmXXXXXAXXXXXA
31000Sensor-Activated PistonXXXXXAXXXXXA
31666Laser DivertorXXXXXAXXXXXA
38200Laser-Activated PistonXXXXXAXXXXXA
42005Manually-Activated PistonXXXXXAXXXXXA
12834XS2 Servo MotorXXXXXXB
21032Manual Servo MotorXXXXXXB
21042Manual Servo Motor IIXXXXXXB
24783XS3 Servo MotorXXXXXXB
32220XS4 Servo MotorXXXXXXB
35599Auto Servo MotorXXXXXXXB
19283Photoelectric DetectorXXXXC
19299Ionization DetectorXXXXXC
23756Fiber Optic Visual SensorXXXXXXC
25030Radon DetectorXXXXC
34556Carbon Monoxide DetectorXXXXXC
45890Motion DetectorXXXXC
(3) Content Matrix
ACME Supply Company
NameHand DeburPaintWeldingMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
ASensor-Activated Arm30604590140130110X605
BLaser-Activated Arm30603060140100110X530
CManually-Activated Arm45604012015090100X605
DBar Code Diverter Piston30603590180140110X645
EBar Code Diverter Arm606045100180105105X655
FSensor-Activated Piston306040851059090X500
GLaser-Activated Piston306035150130140200X745
HManually-Activated Piston30603580145100100X550
ILaser Diverter30604024030024080X990
XCustom Orders306030120160105110X615
(4) Remove Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
18392Sensor-Activated Arm4560309014013025X520
21000Laser-Activated Arm3060306014010045X465
22020Manually-Activated Arm4060451201759060X590
28121Bar Code Divertor Piston356030902409030X575
30000Bar Code Divertor Arm45606010018010530X580
31000Sensor-Activated Piston406030651259045X455
31666Laser Divertor40603024030024030X940
38200Laser-Activated Piston356030120180125110X660
42005Manually-Activated Piston3560308014510045X495
Move to another product family
(5) Final Matrix
ACME Supply Company
FINAL MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL
18392Sensor-Activated Arm4560309014013025X520
21000Laser-Activated Arm3060306014010045X465
22020Manually-Activated Arm4060451201759060X590
28121Bar Code Divertor Piston356030902409030X575
30000Bar Code Divertor Arm45606010018010530X580
31000Sensor-Activated Piston406030651259045X455
38200Laser-Activated Piston356030120180125110X660
42005Manually-Activated Piston3560308014510045X495
(6) Final Matrix Cell
ACME Supply Company
FINAL MATRIX
P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTALCell TimesCell Cycle TimeDemand
18392Sensor-Activated Arm4560309014013025X520430
21000Laser-Activated Arm3060306014010045X465375
22020Manually-Activated Arm4060451201759060X590485
28121Bar Code Divertor Piston356030902409030X575485
30000Bar Code Divertor Arm45606010018010530X580460
31000Sensor-Activated Piston406030651259045X455365
38200Laser-Activated Piston356030120180125110X660570
42005Manually-Activated Piston3560308014510045X495
485
total work
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXX
WeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
DescriptionP/NQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
Sensor-Activated Arm18392653004532256590585065140910065130845065180117005851065ABC
Laser-Activated Arm210008530030285085605100851601360085100850085240204005901085ABC
Manually-Activated Arm2202035300401700351204200351756125359031503522077006451135ABC
Bar Code Divertor Piston28121703003527507090630070240168007090630070200140006551170SS
Bar Code Divertor Arm30000503004525505010050005018090005010552505018090006101050SS
Sensor-Activated Piston310005530040250055653575551256875559049505524013200560955SS
Laser-Activated Piston38200203003510002012024002018036002012525002048096009401620SS
Manually-Activated Piston4200525300351175258020002514536252510025002524060006001025SS
Custom Orders (10%)XXX45300301650459542754516072004510547254522099006101045Custom
TOTAL TIMEWct=37.111111111119400Wct=8638700Wct=168.722222222275925Wct=102.944444444446325Wct=225.555555555610150062010450
TOTAL QUANTITY450450450450450
W=540004860054000540005400054000
PROCESS PACE TIME108.0120.0120.0120.0120.0
RESOURCES0.400.721.410.861.88
REVISED:6/21/01
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:30-45 range
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:%Uptime = 90%
Summary
(7) ACME Process Map
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXXXXXX
Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburPaintFinal AssemblyConfigure & Test
DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
Sensor-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065603600750065130845065180117006911265ABC
Laser-Activated Arm210008995%360030627885270012785853003028508560510085160136008530255085603600870085100850085240204007111285ABC
Manually-Activated Arm220203795%360045525435270012735353004017003512042003517561253520700356036005700359031503522077007711335ABC
Bar Code Divertor Piston281217495%36003058057027001277070300352750709063007024016800701510507060360078007090630070200140007611370SS
Bar Code Divertor Arm300005395%36005564885027001275050300452550501005000501809000503015005060360066005010552505018090007561350SS
Sensor-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505560360069005590495055240132006911255SS
Laser-Activated Piston382002195%36006048602027001272020300351000201202400201803600201530020603600480020125250020480960010761820SS
Manually-Activated Piston420052695%360040465025270012725253003511752580200025145362525102502560360051002510025002524060007111225SS
Custom Orders (10%)XXX4795%3600556199452700127454530030165045954275451607200453013504560360063004510547254522099007561345Custom
TOTAL TIME5258624750Wct=37.111111111119400Wct=8638700Wct=168.722222222275925890059400Wct=102.944444444446325Wct=225.55555555561015006924115450
TOTAL QUANTITY473450450450450450450450450
W=54000478085472048600540005400054000486005400054000
PROCESS PACE TIME101.2121.6108.0120.0120.0120.0108.0120.0120.0
RESOURCES1.100.450.400.721.410.161.220.861.88
REVISED:6/21/01BAM
&LRev B&CPrepared By: BAM -- Duggan && Associates Inc.&R&D
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:100T press83% uptime95% Yield
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:95% uptime 2 shifts 8 hours/shift
Brian A. Moffitt:150T press95% uptime
Brian A. Moffitt:83% Uptime2 shifts8 hours/shift
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:%Uptime = 90%
Brian A. Moffitt:90% uptime
Brian A. Moffitt:30-45 range
Summary
(8) Summary
DeburPaint
0.161.22
StampWeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
0.450.400.721.410.861.88
Injection Mold
1.10GO TO PROCESS MAP
TOTAL RESOURCES:8.20
&LPerkin Elmer Instruments&CProcess Map Summary Sheet&RLean GC
&LPrepared By: BAM -- Duggan && Associates Inc.&R&D
GO TO PROCESS MAP
-
© 2018 Institute for Operational Excellence. All Right Reserved.
Current State Map
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© 2018 Institute for Operational Excellence. All Right Reserved.
Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10. How do we deal with changes in customer demand?
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© 2018 Institute for Operational Excellence. All Right Reserved.
Takt Time for the Mix
• Takt time = customer demand rate for the entire family.
• Need to select time period and understand limits of the mix
• Set a ‘Takt Capability’ in terms of Mix and volume to handle different mixes
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Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10. How do we deal with changes in customer demand?
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Determining Equipment Needs
Name Conf
igur
e &
Tes
t C/T
DEM
AND
Conf
igur
e &
Tes
t To
tal T
ime
A Sensor-Activated Arm 110 65 7150
B Laser-Activated Arm
C Manually-Activated Arm
D Bar Code Diverter Piston
E Bar Code Diverter Arm
F Sensor-Activated Piston
G Laser-Activated Piston
H Manually-Activated Piston
X Custom Orders
TIME NEEDED
Effective Working Time
Machines RequiredSum
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(1) X Map
ACME Supply Company
PRODUCT FAMILY MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShip
12834XS2 Servo MotorXXXXXX
18392LED-Activated ArmXXXXXXAXXXX
19283Photoelectric DetectorXXXX
19299Ionization DetectorXXXXX
21000Laser-Activated ArmXXXXXXXXXX
21032Manual Servo MotorXXXXXX
21042Manual Servo Motor IIXXXXXX
22020Manually-Activated ArmXXXXXXAXXXX
23756Fiber Optic Visual SensorXXXXXX
24783XS3 Servo MotorXXXXXX
25030Radon DetectorXXXX
28121Bar Code Divertor PistonXXXXXXAXXXX
30000Bar Code Divertor ArmXXXXXXAXXXX
31000LED-Activated PistonXXXXXXAXXXX
31666Super Laser DivertorXXXXXXXXXX
32220XS4 Servo MotorXXXXXX
34556Carbon Monoxide DetectorXXXXX
35599Auto Servo MotorXXXXXXX
38200Laser-Activated PistonXXXXXXXXXX
42005Manually-Activated PistonXXXXXXAXXXX
45890Motion DetectorXXXX
(2) Sorted X Map
ACME Supply Company
SORTED X MAP
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipFAMILY
18392LED-Activated ArmXXXXXXAXXXXA
21000Laser-Activated ArmXXXXXXXXXXA
22020Manually-Activated ArmXXXXXXAXXXXA
28121Bar Code Divertor PistonXXXXXXAXXXXA
30000Bar Code Divertor ArmXXXXXXAXXXXA
31000LED-Activated PistonXXXXXXAXXXXA
31666Super Laser DivertorXXXXXXXXXXA
38200Laser-Activated PistonXXXXXXXXXXA
42005Manually-Activated PistonXXXXXXAXXXXA
12834XS2 Servo MotorXXXXXXB
21032Manual Servo MotorXXXXXXB
21042Manual Servo Motor IIXXXXXXB
24783XS3 Servo MotorXXXXXXB
32220XS4 Servo MotorXXXXXXB
35599Auto Servo MotorXXXXXXXB
19283Photoelectric DetectorXXXXC
19299Ionization DetectorXXXXXC
23756Fiber Optic Visual SensorXXXXXXC
25030Radon DetectorXXXXC
34556Carbon Monoxide DetectorXXXXXC
45890Motion DetectorXXXXC
(3) Content Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL
18392LED-Activated Arm351459014010A3060130180X691
21000Laser-Activated Arm30130601603060100300X771
22020Manually-Activated Arm4514012017520A456090220X771
28121Bar Code Diverter Piston301359024015A306090300X861
30000Bar Code Diverter Arm5514510018030A6060105180X756
31000LED-Activated Piston601406512510A306090240X691
31666Super Laser Diverter6014024030030602404801451
38200Laser-Activated Piston601351201803060125480X1091
42005Manually-Activated Piston401358014510A3060100240X711
Work content is not within 80%.
(4) Remove Matrix
ACME Supply Company
WORK CONTENT MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL
18392LED-Activated Arm351459014010A3060130180X691
21000Laser-Activated Arm30130601603060100300X771
22020Manually-Activated Arm4514012017520A456090220X771
28121Bar Code Divertor Piston301359024015A306090300X861
30000Bar Code Divertor Arm5514510018030A6060105180X756
31000LED-Activated Piston601406512510A306090240X691
31666Super Laser Divertor6014024030030602404801451
38200Laser-Activated Piston601351201803060125480X1091
42005Manually-Activated Piston401358014510A3060100240X711
Move to another product family
(5) Final Matrix
ACME Supply Company
WORK CONTENT & DEMAND MATRIX
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTALDEMAND
18392LED-Activated Arm351459014010A3060130180X69165
21000Laser-Activated Arm30130601603060100300X77185
22020Manually-Activated Arm4514012017520A456090220X77135
28121Bar Code Divertor Piston301359024015A306090300X86170
30000Bar Code Divertor Arm5514510018030A6060105180X75650
31000LED-Activated Piston601406512510A306090240X69155
38200Laser-Activated Piston601351201803060125480X109120
42005Manually-Activated Piston401358014510A3060100240X71125
VariousCustom Orders551309516030A3060105220X75645
(6) Resource Matrix
P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyElectrical Assy Run TimeDeburrHand DeburrPaintFinal AssyConfigure & Test C/TDEMANDConfigure & Test Total Time
18392ASensor-Activated Arm3514590140910010A3060130110657150
21000BLaser-Activated Arm301306016003060100
22020CManually-Activated Arm45140120175020A456090
28121DBar Code Diverter Piston3013590240015A306090
30000EBar Code Diverter Arm55145100180030A6060105
31000FSensor-Activated Piston6014065125010A306090
38200GLaser-Activated Piston6013512018003060125
42005HManually-Activated Piston4013580145010A3060100
VariousXCustom Orders5513095160030A3060105
9100TIME NEEDED
Effective Working Time
Machines Required
(7) ACME Process Map
Process MapSummaryLean ACME
ACME SUPPLY CO.
Times in seconds unless notedXXXXXXXXXX
Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburHand DeburPaintFinal AssemblyConfigure & Test
DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer
LED-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065065603600750065130845065180117006911265ABC
Laser-Activated Arm210008995%360030627885270012785853003028508560510085160136008530255085603600870085100850085300255007711385ABC
Manually-Activated Arm220203795%360045525435270012735353004017003512042003517561253520700350356036005700359031503522077007711335ABC
Bar Code Divertor Piston281217495%36003058057027001277070300352750709063007024016800701510507007060360078007090630070300210008611470SS
Bar Code Divertor Arm300005395%36005564885027001275050300452550501005000501809000503015005005060360066005010552505018090007561350SS
LED-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505505560360069005590495055240132006911255SS
Laser-Activated Piston382002195%36006048602027001272020300351000201202400201803600203060020603600480020125250020480960010911820SS
Manually-Activated Piston420052695%360040465025270012725253003511752580200025145362525102502502560360051002510025002524060007111225SS
Custom Orders (10%)XXX4795%3600556199452700127454530030165045954275451607200453013504504560360063004510547254522099007561345Custom
TOTAL TIME5258624750Wct=37.111111111119400Wct=8638700Wct=168.7222222222759256050315059400Wct=102.944444444446325Wct=252.44444444441136007099118450
TOTAL QUANTITY473450450450450345450450450450
W=5400047808547204860054000540005400054000486005400054000
PROCESS PACE TIME101.2121.6108.0120.0120.0156.5120.0108.0120.0120.0
RESOURCES1.100.450.400.721.410.110.061.220.862.10
REVISED:6/21/01BAM
&LRev B&CPrepared By: BAM -- Duggan && Associates Inc.&R&D
Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes
Brian A. Moffitt:100T press83% uptime95% Yield
Brian A. Moffitt:Range 120-240 sec
Brian A. Moffitt:Range: 90-130 sec
Brian A. Moffitt:Range: 60-120 sec
Brian A. Moffitt:95% uptime 2 shifts 8 hours/shift
Brian A. Moffitt:150T press95% uptime
Brian A. Moffitt:83% Uptime2 shifts8 hours/shift
Brian A. Moffitt:Uptime = 90%Changeovers = 5 min
Brian A. Moffitt:%Uptime = 90%
Brian A. Moffitt:90% uptime
Brian A. Moffitt:30-45 range
Summary
(8) Summary
DeburPaintHand Debur
0.111.220.06
StampWeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test
0.450.400.721.410.862.10
Injection Mold
1.10GO TO PROCESS MAP
TOTAL RESOURCES:8.43
&LPerkin Elmer Instruments&CProcess Map Summary Sheet&RLean GC
&LPrepared By: BAM -- Duggan && Associates Inc.&R&D
GO TO PROCESS MAP
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© 2018 Institute for Operational Excellence. All Right Reserved.
Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10. How do we deal with changes in customer demand?
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Interval for the Mix
• In a mix environment we must define the Interval in which the pacemaker will run the mix of products.
• The concept of the interval must be clearly understood.• You may have hear the term ‘EPEI’ which stands for
Every Product Every Interval.
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The Interval
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The Interval
1 Week
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The Interval
1 DayCo
pyrig
ht 20
18 In
stitut
e for
Opera
tiona
l Exc
ellen
ce
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© 2018 Institute for Operational Excellence. All Right Reserved.
Is there Enough Time for Changeovers?
We would compare the total time needed to the effective working time per interval. Any left over time can be used for changeovers.
Effective working time per interval
Total time needed per interval
Time left for changeovers
Machine station
Time900 min.
800 min.100 min.
10 Products in the Family
Max C/O time = 10 min.
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Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10. How do we deal with changes in customer demand?
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tute f
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ence
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How will we Flow Work through the Pacemaker?
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Balance Charts
Current State
Common Tools
Future State
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Current State Future State
Operator Balance Chart - Part B(Laser-Activated Arm)
140 sec.Takt = 120 sec.
110 sec.100 sec.
Elect.Assembly
Final60 sec. Assembly Config
& TestMech.
30 sec. Assembly
Welding
Operator Balance Chart - Part B(Laser-Activated Arm)
Takt = 120 sec.
110 sec. 110 sec. 110 sec.
FinalElect. Assembly
Assembly
65 sec.Mech. Config.
Assembly Elect. & TestAssembly
FinalAssembly
Welding
Eliminate Walking
Common Tools
Operator Balance Chart - Part A (Sensor-Activated Arm)
140 sec.Takt = 120 sec. 130 sec.
110 sec.
90 sec. Elect.Assembly Final
AssemblyConfig
Mech. & Test45 sec. Assembly
Welding
Operator Balance Chart - Part A (Sensor-Activated Arm)
Takt = 120 sec.
110 sec. 110 sec. 110 sec.
100 sec.
Mech. Elect. FinalAssembly Assembly Assembly
Config.& Test
Welding
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Work Content Times by Process
WORK CONTENT BY PROCESS
(CURRENT STATE)
PARTWELDPAINTHAND DEBURRMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TEST
A45603090140130110605405
B30603060140100110530330
C40604512015090100605400
D35603090180140110645445
E456060100180105105655430
F406030851259090520340
G356030150130140200745455
H35603080145100100550360
CUSTOM456030120160105110630430
WORK CONTENT BY PROCESS
(FUTURE STATE)
PARTWELDMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TESTWC % Reduction
A357511010011043032026.56%
B25501209011039528515.79%
C301001108510042532523.08%
D30901601251105154059.88%
E40751407510543533030.30%
F358012085904103206.25%
G301351301402006354354.60%
H30701259510042032012.50%
CUSTOM35901109011043532532.31%
B-Charts-Current All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
140 sec.140 sec.
Takt = 120 sec.130 sec.Takt = 120 sec.
110 sec.110 sec.
100 sec.
90 sec.Elect.Elect.
AssemblyFinalAssembly
AssemblyFinal
Config60 sec.AssemblyConfig
Mech.& Test& Test
45 sec.AssemblyMech.
30 sec.Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
180 sec.
150 sec.
140 sec.
Takt = 120 sec.Takt = 120 sec.
120 sec.
110 sec.
Elect.100 sec.Elect.
Assembly90 sec.90 sec.Assembly
Mech.
AssemblyFinalFinal
AssemblyConfigMech.AssemblyConfig
& TestAssembly& Test
40 sec.35 sec.
WeldingWelding
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
180 sec.
Takt = 120 sec.Takt = 120 sec.125 sec.
105 sec.105 sec.
100 sec.Elect.90 sec.
Assembly85 sec.Elect.90 sec.
Assembly
Final
Mech.AssemblyConfigFinalConfig
45 sec.Assembly& TestAssembly& Test
40 sec.Mech.
WeldingAssembly
Welding
Operator Balance Chart - Part GOperator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
200 sec.
150 sec.
140 sec.
130 sec.145 sec.
Takt = 120 sec.Takt = 120 sec.
Elect.Elect.100 sec.100 sec.
AssemblyAssembly
Final80 sec.
AssemblyFinal
Mech.ConfigAssemblyConfig
Assembly& TestMech.& Test
35 sec.35 sec.Assembly
WeldingWelding
B-Charts-Future All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
100 sec.Final
Elect.Assembly
Assembly
Mech.Elect.Final
AssemblyAssemblyAssembly
Config.
& Test
65 sec.
Mech.Config.
AssemblyElect.& Test
Assembly
Final
Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Elect.
Mech.AssemblyFinal
AssemblyMech.Elect.Assembly75 sec.Config.
AssemblyAssembly& Test
FinalConfig.
Assembly& Test
Final
Elect.Assembly
Assembly
WeldingWelding
Mech.Elect.
AssemblyAssembly
`
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Config.
& Test90 sec.
Mech.Elect.Mech.
AssemblyAssemblyFinalAssemblyConfig.
Assembly& Test
Elect.
Assembly
Final
Assembly
Welding
Elect.
AssemblyWelding
Elect.
Assembly
Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.100 sec.
Final
Assembly
Mech.Elect.Mech.Final
AssemblyAssemblyAssemblyAssembly
FinalElect.Config.
AssemblyAssembly& Test
Elect.
Assembly
Mech.
AssemblyConfig.Welding
Welding& Test
Work Content Times by Process
WORK CONTENT BY PROCESS
(CURRENT STATE)
PARTWELDPAINTHAND DEBURRMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TEST
A45603090140130110605405
B30603060140100110530330
C40604512015090100605400
D35603090180140110645445
E456060100180105105655430
F406030851259090520340
G356030150130140200745455
H35603080145100100550360
CUSTOM456030120160105110630430
WORK CONTENT BY PROCESS
(FUTURE STATE)
PARTWELDMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TESTWC % Reduction
A357511010011043032026.56%
B25501209011039528515.79%
C301001108510042532523.08%
D30901601251105154059.88%
E40751407510543533030.30%
F358012085904103206.25%
G301351301402006354354.60%
H30701259510042032012.50%
CUSTOM35901109011043532532.31%
B-Charts-Current All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
140 sec.140 sec.
Takt = 120 sec.130 sec.Takt = 120 sec.
110 sec.110 sec.
100 sec.
90 sec.Elect.Elect.
AssemblyFinalAssembly
AssemblyFinal
Config60 sec.AssemblyConfig
Mech.& Test& Test
45 sec.AssemblyMech.
30 sec.Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
180 sec.
150 sec.
140 sec.
Takt = 120 sec.Takt = 120 sec.
120 sec.
110 sec.
Elect.100 sec.Elect.
Assembly90 sec.90 sec.Assembly
Mech.
AssemblyFinalFinal
AssemblyConfigMech.AssemblyConfig
& TestAssembly& Test
40 sec.35 sec.
WeldingWelding
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
180 sec.
Takt = 120 sec.Takt = 120 sec.125 sec.
105 sec.105 sec.
100 sec.Elect.90 sec.
Assembly85 sec.Elect.90 sec.
Assembly
Final
Mech.AssemblyConfigFinalConfig
45 sec.Assembly& TestAssembly& Test
40 sec.Mech.
WeldingAssembly
Welding
Operator Balance Chart - Part GOperator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
200 sec.
150 sec.
140 sec.
130 sec.145 sec.
Takt = 120 sec.Takt = 120 sec.
Elect.Elect.100 sec.100 sec.
AssemblyAssembly
Final80 sec.
AssemblyFinal
Mech.ConfigAssemblyConfig
Assembly& TestMech.& Test
35 sec.35 sec.Assembly
WeldingWelding
B-Charts-Future All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
100 sec.Final
Elect.Assembly
Assembly
Mech.Elect.Final
AssemblyAssemblyAssembly
Config.
& Test
65 sec.
Mech.Config.
AssemblyElect.& Test
Assembly
Final
Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Elect.
Mech.AssemblyFinal
AssemblyMech.Elect.Assembly75 sec.Config.
AssemblyAssembly& Test
FinalConfig.
Assembly& Test
Final
Elect.Assembly
Assembly
WeldingWelding
Mech.Elect.
AssemblyAssembly
`
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Config.
& Test90 sec.
Mech.Elect.Mech.
AssemblyAssemblyFinalAssemblyConfig.
Assembly& Test
Elect.
Assembly
Final
Assembly
Welding
Elect.
AssemblyWelding
Elect.
Assembly
Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.100 sec.
Final
Assembly
Mech.Elect.Mech.Final
AssemblyAssemblyAssemblyAssembly
FinalElect.Config.
AssemblyAssembly& Test
Elect.
Assembly
Mech.
AssemblyConfig.Welding
Welding& Test
Work Content Times by Process
WORK CONTENT BY PROCESS
(CURRENT STATE)
PARTWELDPAINTHAND DEBURRMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TEST
A45603090140130110605405
B30603060140100110530330
C40604512015090100605400
D35603090180140110645445
E456060100180105105655430
F406030851259090520340
G356030150130140200745455
H35603080145100100550360
CUSTOM456030120160105110630430
WORK CONTENT BY PROCESS
(FUTURE STATE)
PARTWELDMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TESTWC % Reduction
A357511010011043032026.56%
B25501209011039528515.79%
C301001108510042532523.08%
D30901601251105154059.88%
E40751407510543533030.30%
F358012085904103206.25%
G301351301402006354354.60%
H30701259510042032012.50%
CUSTOM35901109011043532532.31%
B-Charts-Current All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
140 sec.140 sec.
Takt = 120 sec.130 sec.Takt = 120 sec.
110 sec.110 sec.
100 sec.
90 sec.Elect.Elect.
AssemblyFinalAssembly
AssemblyFinal
Config60 sec.AssemblyConfig
Mech.& Test& Test
45 sec.AssemblyMech.
30 sec.Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
180 sec.
150 sec.
140 sec.
Takt = 120 sec.Takt = 120 sec.
120 sec.
110 sec.
Elect.100 sec.Elect.
Assembly90 sec.90 sec.Assembly
Mech.
AssemblyFinalFinal
AssemblyConfigMech.AssemblyConfig
& TestAssembly& Test
40 sec.35 sec.
WeldingWelding
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
180 sec.
Takt = 120 sec.Takt = 120 sec.125 sec.
105 sec.105 sec.
100 sec.Elect.90 sec.
Assembly85 sec.Elect.90 sec.
Assembly
Final
Mech.AssemblyConfigFinalConfig
45 sec.Assembly& TestAssembly& Test
40 sec.Mech.
WeldingAssembly
Welding
Operator Balance Chart - Part GOperator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
200 sec.
150 sec.
140 sec.
130 sec.145 sec.
Takt = 120 sec.Takt = 120 sec.
Elect.Elect.100 sec.100 sec.
AssemblyAssembly
Final80 sec.
AssemblyFinal
Mech.ConfigAssemblyConfig
Assembly& TestMech.& Test
35 sec.35 sec.Assembly
WeldingWelding
B-Charts-Future All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
100 sec.Final
Elect.Assembly
Assembly
Mech.Elect.Final
AssemblyAssemblyAssembly
Config.
& Test
65 sec.
Mech.Config.
AssemblyElect.& Test
Assembly
Final
Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Elect.
Mech.AssemblyFinal
AssemblyMech.Elect.Assembly75 sec.Config.
AssemblyAssembly& Test
FinalConfig.
Assembly& Test
Final
Elect.Assembly
Assembly
WeldingWelding
Mech.Elect.
AssemblyAssembly
`
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Config.
& Test90 sec.
Mech.Elect.Mech.
AssemblyAssemblyFinalAssemblyConfig.
Assembly& Test
Elect.
Assembly
Final
Assembly
Welding
Elect.
AssemblyWelding
Elect.
Assembly
Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.100 sec.
Final
Assembly
Mech.Elect.Mech.Final
AssemblyAssemblyAssemblyAssembly
FinalElect.Config.
AssemblyAssembly& Test
Elect.
Assembly
Mech.
AssemblyConfig.Welding
Welding& Test
Work Content Times by Process
WORK CONTENT BY PROCESS
(CURRENT STATE)
PARTWELDPAINTHAND DEBURRMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TEST
A45603090140130110605405
B30603060140100110530330
C40604512015090100605400
D35603090180140110645445
E456060100180105105655430
F406030851259090520340
G356030150130140200745455
H35603080145100100550360
CUSTOM456030120160105110630430
WORK CONTENT BY PROCESS
(FUTURE STATE)
PARTWELDMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TESTWC % Reduction
A357511010011043032026.56%
B25501209011039528515.79%
C301001108510042532523.08%
D30901601251105154059.88%
E40751407510543533030.30%
F358012085904103206.25%
G301351301402006354354.60%
H30701259510042032012.50%
CUSTOM35901109011043532532.31%
B-Charts-Current All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
140 sec.140 sec.
Takt = 120 sec.130 sec.Takt = 120 sec.
110 sec.110 sec.
100 sec.
90 sec.Elect.Elect.
AssemblyFinalAssembly
AssemblyFinal
Config60 sec.AssemblyConfig
Mech.& Test& Test
45 sec.AssemblyMech.
30 sec.Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
180 sec.
150 sec.
140 sec.
Takt = 120 sec.Takt = 120 sec.
120 sec.
110 sec.
Elect.100 sec.Elect.
Assembly90 sec.90 sec.Assembly
Mech.
AssemblyFinalFinal
AssemblyConfigMech.AssemblyConfig
& TestAssembly& Test
40 sec.35 sec.
WeldingWelding
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
180 sec.
Takt = 120 sec.Takt = 120 sec.125 sec.
105 sec.105 sec.
100 sec.Elect.90 sec.
Assembly85 sec.Elect.90 sec.
Assembly
Final
Mech.AssemblyConfigFinalConfig
45 sec.Assembly& TestAssembly& Test
40 sec.Mech.
WeldingAssembly
Welding
Operator Balance Chart - Part GOperator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
200 sec.
150 sec.
140 sec.
130 sec.145 sec.
Takt = 120 sec.Takt = 120 sec.
Elect.Elect.100 sec.100 sec.
AssemblyAssembly
Final80 sec.
AssemblyFinal
Mech.ConfigAssemblyConfig
Assembly& TestMech.& Test
35 sec.35 sec.Assembly
WeldingWelding
B-Charts-Future All Products
Operator Balance Chart - Part AOperator Balance Chart - Part B
(Sensor-Activated Arm)(Laser-Activated Arm)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
100 sec.Final
Elect.Assembly
Assembly
Mech.Elect.Final
AssemblyAssemblyAssembly
Config.
& Test
65 sec.
Mech.Config.
AssemblyElect.& Test
Assembly
Final
Assembly
Welding
Welding
Operator Balance Chart - Part COperator Balance Chart - Part D
(Manual-Activated Arm)(Bar Code Diverter Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Elect.
Mech.AssemblyFinal
AssemblyMech.Elect.Assembly75 sec.Config.
AssemblyAssembly& Test
FinalConfig.
Assembly& Test
Final
Elect.Assembly
Assembly
WeldingWelding
Mech.Elect.
AssemblyAssembly
`
Operator Balance Chart - Part EOperator Balance Chart - Part F
(Bar Code Diverter Arm)(Sensor-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.
Config.
& Test90 sec.
Mech.Elect.Mech.
AssemblyAssemblyFinalAssemblyConfig.
Assembly& Test
Elect.
Assembly
Final
Assembly
Welding
Elect.
AssemblyWelding
Elect.
Assembly
Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H
(Laser Activated Piston)(Manually-Activated Piston)
Takt = 120 sec.Takt = 120 sec.
110 sec.110 sec.110 sec.110 sec.110 sec.
105 sec.
100 sec.100 sec.
Final
Assembly
Mech.Elect.Mech.Final
AssemblyAssemblyAssemblyAssembly
FinalElect.Config.
AssemblyAssembly& Test
Elect.
Assembly
Mech.
AssemblyConfig.Welding
Welding& Test
-
© 2018 Institute for Operational Excellence. All Right Reserved.
Machine Cycle Times
Products with a high cycle time at a station may exceed mix takt time.
Testing
200 sec.
Takt Time = 120 sec.
Bottleneck
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Balancing Machine Cycle Times
• Some products have a higher Test cycle time than takttime
• A small FIFO lane absorbs the mix difference in machine times
• FIFO Lane sized to the interval
FIFO
90 -150 seconds
Pacemaker
90 – 200 seconds
Test
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Key Questions and our Agenda
1. Do you have the right product families?
2. What is the takt time at the pacemaker?
3. Can the equipment support takt time?
4. What is the interval?
5. What are the balance charts for the products?
6. How will we balance flow for the mix?
7. How will we create standard work for the mix?
8. How will we create pitch at the pacemaker?
9. How do we schedule the mix at the pacemaker?
10. How do we deal with changes in customer demand?
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Balancing Flow for the Mix
Since the labor content varies and not all products can be balanced to takt time, we must decide the best way to
balance the products based on our business.
Let’s look at balancing options…
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Balancing Examples
Level the schedule and keep labor constant, build products in order:
FIFO90 -150 seconds
Level mix,sequence ordersbased on work content and pull signals
Pacemaker Ship
A C B A C B A C B
Output varies based on work
content
# Operators always constant
90 – 200 Seconds
Test
Option # 1:• Discrete Parts• Low Demand Variation• High Volume
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Balancing Examples
Balance to the takt time and add labor when a product exceeds the takt time. Try to build products to demand.
Option # 2:• Discrete Parts• Custom Parts• High Demand Variation• Short Lead Times
FIFO110 seconds
Build to demand as much as possible
Pa