flexible manufacturing is a systematic€¦ · reduction and also known as quick changeover . •...
TRANSCRIPT
Flexible Manufacturing is a systematic establishment where the operation will be
able to react positively in the case of changes, whether predicted or unpredicted.
Flexible Manufacturing is a systematic establishment where the operation will be
able to react positively in the case of changes, whether predicted or unpredicted.
P7 – FLEXIBILITY
INTRODUCTION
The system’s ability to change to produce new product types and ability to change the order of operation executed on a part.
1st Category : Resources Flexibility
2nd Category : Routing Flexibility
The ability to use multiple facilities to perform same operation on part, as well as the system’s ability to absorb large scale changes, such as in volume or capability.
P7 – FLEXIBILITY
FLEXIBILITY CATEGORY
OBJECTIVE & BENEFITS
1. Optimizing Human Resources Capabilities
2. Maximizing Usage Of Machines And Tools
3. Optimizing Process Capabilities
4. Maximizing Usage Of Material
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1. Optimizing Human Resources Capabilities
FMS will drive the organization to develop multi-skillsemployees where employees have ability to perform variousjob functions or processes. With multi-skills employees,every organization is able to :
� Fulfill any vacancy in the management or operation withinshort period.
� Improve on-job training efficiencies.
� Reduce man-hour loss time due to skill learning processes.
OBJECTIVE & BENEFITS
2. Maximizing Usage Of Machines And Tools
With the implementation of FMS, the organization willindirectly encourage development team to continuouslydetermine existing facilities and resources capability whenconduct new product or process development and able to :
� Improve design capability by improving design conceptinput.
� Eliminate purchase of unnecessary or unutilized machinesand tools.
� Reduce cost of machines and tools management.
OBJECTIVE & BENEFITS
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3 Optimizing Process Capabilities
FMS will determine approved alternative processes (man-power, machine or tool, material and method) when failure ofstandard processes occurred. Availability of processes 4Melements successor plan will :
� Minimizing processes from stoppage caused by 4Mfactors.
� Conduct systematic training program.
� Provide on time preventive and plan maintenance.
OBJECTIVE & BENEFITS
4. Maximizing Usage Of Material
Material can be determined as packing material for rawmaterial, parts from suppliers, work in progress parts, subprocess parts or finish good parts. Commonization of thesematerial will resulting :
� Reduction of material storage management cost.
� Less control standard and minimize human error.
� Eliminate purchase of unnecessary or unutilized packingmaterial, rack and others.
OBJECTIVE & BENEFITS
OP5
OP4
OP3
OP2
OP1
Product ABC
OP3
OP2
OP1
Product B
OP4
OP3
OP2
OP1
Product BC
Limited skill of operator
Multi operational machines.
Multi skills operator.
OP5
OP4
OP3
OP2
OP1
Product A
OP3
OP2
OP1
Product B
OP4
OP3
OP2
OP1
Product C
Dedicated machines and lines
EXAMPLE OF NON FLEXIBLE
SYSTEM
EXAMPLE OF RESOURCE FLEXIBLE SYSTEM
Skills operator.
Resource Flexibility
P7 – FLEXIBILITY
FLEXIBILITY CATEGORY
OP5
OP4
OP3
OP2
OP1
Product A
OP3
OP2
OP1
Product B
OP4
OP3
OP2
OP1
Product C
Dedicated machines and lines
EXAMPLE OF NON FLEXIBLE
SYSTEM
OP5
OP4
OP3
OP2
OP1
Product A
OP3
OP2
OP1
Product B
OP4
OP3
OP2
OP1
Product C
Dedicated machines and lines
EXAMPLE OF ROUTING
FLEXIBILITY SYSTEM
Skills operator.
.eg. :When volume for Product A,B drastically increase and the bottle neck are OP1~3, Line Product B shall be able to support at any time.
Routing Flexibility
P7 – FLEXIBILITY
FLEXIBILITY CATEGORY
RESOURCES KEY FLEXIBILITY
WORKERAble and ready to perform many processes processes when required. I.e Multi skills .
RAW MATERIAL Fully utilize raw material. I.e More stamping parts can be produced from same types of coil.
MACHINE AND TOOLING
Being set up or design to maximize utilization by considering multiple parts or products to produce
MANUFACTURING METHOD
Able to meet production requirements such as increasing or decreasing of volume by auto adjusting processes.
ENVIRONMENTProvided space areas that minimizing processes re-layout cost when required due to drastic changes of volume.
P7 – FLEXIBILITY
RESOURCES
1. Mix Model Production
2. Kitting
3. Enterprise Resources Planning (ERP)
4. Single Minute Exchange Die (SMED)
1. Mix Model Production
2. Kitting
3. Enterprise Resources Planning (ERP)
4. Single Minute Exchange Die (SMED)
P7 – FLEXIBILITY
FLEXIBILITY INITIATIVES
1. To ensure FMS function effectively, a group of engineer shall be formed and this group normally called industrial engineering group.
2. Selected engineers shall have a knowledges with manufacturing processes and core resources.
3. Important tools applies for fms designing are : 1. Process FMEA2. PDCA concept3. VA / VE4. VSM5. Lean manufacturing6. Kitting system ( if necessary )
P7 – FLEXIBILITY
EFFECTIVE DESIGN
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Kitting System
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Kitting Supply System L1
Kitting supply system is one of the systematic material supply methods use -From material storage to production line.
� Kitting is suitable for production line which :- Comprises of many processes- Assemble of many parts or components- Need high efficiency of producing output- High potential of miss assemble
Advantage of Kitting:
� Potential to maximize productivity by :- Focused operator to their work scope- Consistent machine operation- Efficient material supply system- Process ownership methodology - Harmony working environment
Objective of Kitting Supply System L1
The objectives of kit supply applications:� Minimize operator movement.� Increase process ownership.� Develop workers to work with similar rhythm and consistently
productive.� Eliminate miss-assemble product from being released to customer.� Eliminate shortage or excess parts from being supplied to
production.� Productivity improvement control.� Improve 5S condition.
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1. Supply Bucket 2. Supply Trolley
1. Kit Part 2. Kit Bucket 3. Kit Trolley
1. Kit Rack 2. Kit Stand
a) INCOMING PART SUPPLY STATION
b) KIT PREPARATION STATION
c) KIT SUPPLY STATION
Basic Flow and Supply Station L1
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Kit Supply System Implementation Activity
1. Study schedule
2. Current parts flow
3. Kit supply parts flow
4. Kit Supply component definition
5. Factors of 4M
6. Introduction method
7. Concrete idea and benchmarking
8. Study case
9. Cost estimation
10. Other obstacles
L1
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Kit Supply System Implementation Steps L1
Kitting supply system is one of thesystematic material supply methods use -From material storage to production line.
Definition of Kitting System
Photo
Kitting system
Kitting is suitable for production line which :- Comprises of many processes- Assemble of many parts or components- Need high efficiency of producing output- High potential of miss assemble
The objectives of kitting supply applications:
� Minimize operator movement.� Increase process ownership.� Develop workers to work with similar rhythm
and consistently productive.� Eliminate miss-assemble product from being
released to customer.� Eliminate shortage or excess parts from
being supplied to production.� Productivity improvement control.� Improve 5S condition.
Objectives of Kitting system
Basic flow for Kitting system
INCOMING PART SUPPLY
ARRANGE CHILD PARTS INTO KITTING BIN/RACK ACCORDING TO REQUIREMENT
ARRANGE PARTS ONTO KITTING TROLLY
SENT TO PRODUCTION LINE/ WORKSTATION
PRODUCTION USE THE PARTS
Material handler
Material handler
Production operator
Kitting operator
Kitting operator
Basic flow for Kitting system
Incoming Part Arrange part into kitting rack Arrange on the trolley Sent to production
Implementation Activity for Kitting system
1. Study current schedule2. Get current parts flow3. Design kit supply parts flow4. Design Kit supply component5. Study on 4M factors6. Introduction method to user/line7. Check on implementation8. Prepare standard operation procedure (SOP)9. Training & Handover
Definition of SMED
• Single Minute Exchange Die is also known as SetupReduction and also known as Quick Changeover .
• SMED is one of the Lean Manufacturing activities with mainobjective is to eliminate waste .
• It is a method for rapidly and efficiently converting a processfrom running the current product to running the next productwithin less than 10 minutes .
• SMED was originally developed to improve machine toolssetups, but it principles applied to all type of processes.
• Set up can be done quickly, it can be done as often as needed.
• Simpler set up results in safer changeover, withless physical strain or risk of injury.
• Less inventory in workplace, which makeproduction easier.
• Set up tools are standardized and combined,which means fewer tools to keep track of.
• Company can run products in smaller lots.
Benefits of SMED
Basic flow for Implementing SMED
Form the team. � Conduct training and education
Study the setup process
Phase 1 � Can use video tapes
Classify into internal setups and external
setups.
Phase 1� Operation which do
not add values to the setup. Eliminate the waste.
Improve internal setups
Phase 2� Reduce internal setup
by doing more work externally
Improve external setups
Phase 3
� Simplify or eliminate the need for adjustments and tweaking
Basic flow for Implementing SMED
Develop the standard operating procedure
(SOP).
� Fine tune all elements of the setup by training the operators and timing the new setup process.Evaluate the
performance.
Phase 4
Overhead crane transfer coil
Coil standby
Die board standby Basket Standby
Forklift/ Lifter for Die transfer
Cushion pin storage
Die storage
Raw material standby
Die standby
�ERP system
Agenda
Introduction to ERP
Why Company Choose ERP
Benefits
Market Demand for Graduate Student
Implementation of ERP
Conclusion
5
2
3
4
1
6
A way to integrate the data and processes of an organization into one single system
Delivers a single sharing database that contains all data for the software modules which would include:
� Manufacturing
� Supply Chain Management (SCM)
� Financials
� Project Management
� Human Resources
� Customer Relationship Management (CRM)
� Others:
� Access Control
� Customization (Tools)
241
2. Why Company Choose ERP
- 242 -
All business activities & transaction are integrated in one
system
All level can access the data in one source
Real time data. Related party can
access latest info for planning
Easy maintenance
Better analysis & planning i.e
inventory, manpower, logistic
� Single point of entry• One database for all users
� Improve order tracking • Purchase Order : PO issuance -> Inventory receipt -> Costing
• Sales Order : Order acceptance -> Production -> Delivery -> Invoicing
� Increase process efficiency• Eliminates manual job and promotes automation
• Save enormous time and effort in data entry
� Data accuracy• Reducing error as data need only be entered or updated once
• Data such as inventory and ordering will be more reliable
� Immediate information• Faster data lookup
� Increase productivity• Time and resource are shifted to innovating, problem solving and direct service to customer
� Improve planning and forecasting
- 243 -
4. Market Demand for Graduate Student
- 244 -
Fu
ture
Car
eer 1. Most Manufacturing
Company looking for ERP solution
Tre
nd
of
IT i
n M
FG 1. Value added (new
skills, knowledge)
2. High capability to see manufacturing process
3. Enhance problem solving skills& analysis
245
OUTPUT
SCM MFG
FINPRO
JHR
CRMTOOL
S
CE
NT
RA
L
SY
ST
EM
ERPLNINPUT
ME
CH
AN
ISM
Eg:1.Sales Order2.Purchase Order
Eg:1.Delivery Order2. Payment3. Reports
PHN16 Server
1. Auto upload2. Barcode3. Manual
1997
Baan 5c
20032nd Qtr • A
20043rd Qtr • B
4th Qtr • C
A: Finance ModuleB: Distribution ModuleC: Manufacturing Module
Triton Barcode Customized System
ERP LN
2012
December 2013IT Department, 246
2013
Infor Barcode System
Records general transactionsi.e. Accruals, provisions,adjustments and reversals.
Records customers’ billing,invoicing. Updatescustomers details,payments. Reviewcustomers’ aging
Records suppliers’ billing,invoicing. Updatessuppliers’ details, payments.Review suppliers’ aging.
Department’s monthlybudget analysis and control.
Fixed assets’ register updatemonthly budget analysis andcontrol.
Finance ERP Integration
Finance
Pricing
- Business Development update selling price for
invoicing at Finance
Logistics
- Finance create sales order. Logistics convert
delivery order for invoicing.
Purchasing
- Procurement create purchase order for
materials. Logistics convert received for payment process at Finance.
Standard Costing
- Engineering Dept charge rate for Standard
Costing calculation
Modules User
Finance F&S
Warehousing SCM
Sales F&S
Procurement PVD
Manufacturing SCM, Mfg, Engineering, BD
Enterprise Planning SCM
Invoicing F&S
Tools IT
December 2013IT Department, 249
December 2013 - 250 -IT Department,
Customer Order Create SO Check Invt. Bal
Delivery
Invt Available
Invt NA
Create Prod Ord Production
Check Invt. Bal Create PO Receipt
Sales Order
Billing
Release to warehouse
AP
Purchase Order
Order Mgmt Warehousing FinanceManufacturing
F&S, PVD SCM SCM F&S
Delivery Order
Production
DO
Material
ERPLN MODULES
USER DEPT
Sales Delivery - DO