jit tm-007-c1.0-leveling.ppt[1]
TRANSCRIPT
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PRIVATE/PROPRIETARYJIT-TM-007-C1.0-Leveling – Page 1 of 17
APS Training ModuleJIT – Leveling
Autoliv14-April-2006
JIT–TM-007-C1.0
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PRIVATE/PROPRIETARYJIT-TM-007-C1.0 -Leveling– Page 2 of 17
Autoliv
Quality assurance
Quality methods
Six Sigma
Standards
Pull system
Safety & Ergonomy
Don’t judge, don’t blame !
Flexibility & Motivation
Discipline to standards
Continuous improvement
Process & Result
Customers
Company Employees
Society
Quality first
ProfitabilityCompetitiveness
Satisfaction
Employee involvement
Team work 5S Muda elimination TPM
Just in time
Leveling & Capacity
Line concepts
Continuous flow
Takt time
Frequent deliveries
Leveling & Capacity
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Why this training
During this training you will learn:• What is the purpose of leveling?
• What are the three components of leveled production?
• How do we level production?
• What are the benefits of leveling?
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Satisfy customer demand and create stable production while continuously
improving standards
Give the customers:
Purpose of Leveling
• What they want • When they want it• In the quantity they want
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Contract Leveling
Monthly activity Daily activity
Rail Management
Hourly activity
Leveling
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Leveling
Leveling has 3 components:
• Volume
• Variety
• Time
When demand is level, it gives you an opportunity to effectively plan your Manpower, Material, and Machines.
Low Demand
Levelled Production
Without leveling, your capacity must equal the
Highest Demand Balanced Demand
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PRIVATE/PROPRIETARYJIT-TM-007-C1.0-Leveling – Page 7 of 17
Monthly Need
Ref A
100 boxes
Ref B
200 boxes
Ref C
300 boxes
Level1
Level1
20 pallets
40 pallets
60 pallets
Réf A
Réf B
Réf C
MonthOnce a month
each reference
Level2
Level2
10 pallets
20 pallets
30 pallets
10 pallets
20 pallets
30 pallets
Réf A
Réf B
Réf C
MonthMore than once
a month of each reference
Level3
Level3
1 palletRéf A
Réf B
Réf C
Day2 pallets
3 pallets
Once a day
each reference
Level4
Level4
1 pallet
1 pallet
1 pallet 1 pallet
1 pallet 1 pallet
Réf A
Réf B
Réf C
Day All references at least once a day standard batch (equal quantity)
Réf A
Réf B
Réf C
1 box
1 box 1 box
1 box 1 box 1 box
1 box
1 box 1 box
1 box 1 box 1 box
DayReduce size of
batch at the minimum : box, or even single
product...
Level5
Level5
What is Leveling?
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Leveling
Production every WEEK
Stock averageDelivering every DAY
WHY Level 5 (small lot) is better than Level 1 (large lot)?
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Leveling
Production every 2 days
Delivering every DAY
Stock average
Production every WEEK
Stock averageDelivering every DAY
WHY Level 5 (small lot) is better than Level 1 (large lot)?
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500 A30 B260 C
400 A 30 B360 C
390 A80 B320 C
210 pieces lost !
Breakdown !
BA C
500 400100
A C A C A B A C A C
100 100 100 100 100 100 100 100 100 100
ACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACAC
Batch of 10
500 A100 B400 C
500 A100 B400 C
500 A100 B400 C
500 A30 B260 C
400 A30 B360 C
390 A80 B320 C
100%30%65%
80% 30%90%
78%80%80%
- Qty is not good+ Every customer has 80% of need
WHY Level 5 (small lot) is better than
Level 1 (large lot)?
Leveling
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BA C
500 400100
A C A B A C A C A C
100 100 100 100 100 100 100 100 100 100
ACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACAC
Batch of 10=> Planning can easily be changed for productıon10:00 am
Customer Emergency
C CCCCCCC
=> Planning can not easily be changed for productıon
C
WHY Level 5 (small lot) is better than
Level 1 (large lot)?
Leveling
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HOW : ( OUTPUT )AMO : Logistic
AMO : Production
AMO : Production Engineering
AMO
- daily quantity agreement per family and flexibility inside each family- non chaotic supplier demand
- daily quantity agreement per day- Stable number of operators needed every day for the whole month- TAKT TIME for each production line
- Line availability for technical improvement
- Non chaotic activity- Monthly action plan- Team Building
Leveling
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HOW to define the right level ? • What is your criteria for batches ?
→ Change over time ?
→ Criteria with direct labor impact ?
→ Replenishment criteria ?
→ Quality concerns ?
→ Packaging size
Production line must run according to
Takt time, with the best efficiency to
meet customer satisfaction in Quality,
Cost and On Time Delivery
Leveling
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HOW ?• Define a matrix with reference and criteria
Leather Foam with switch without switchRef A x xRef B x xRef C x xRef D x xRef E x xRef F x xRef G x xRef H x xRef I x xRef J x x
NISSAN X31B
Family 1
Family 2
Family 3
Family 4
Logistic Criteria Production Criteria
Supply chain Impact :
- Levelling of material incoming ==> reduce the line stoppage due to lack of material
Productivity Impact :
- production under control - stable number of operators
Leveling
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HOW ?• Define the batch size
(as small as possible)
batch size
Number of
batch/day 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4
Ref ARef BRef CRef D LevellingRef ERef FRef GRef HRef I
Family 4 Ref J 320 3 J J J J J J
D DC
FF
504
270
48
Family 1
Family 2
Family 3
100
5
3
1
BD D B C
F F E
G
ContractQty/day
G
E
A A
• Change over are forecasted, production is becoming predictable
• Logistic can put any reference related to a family within a family batch
• Level batches in the
Heijunka board
Total 12 batches 1 2 3 4 5 6 7 8 9 10 11 12
Leveling
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• Production under control
• Change over under control
• Planning flexibility within a family
Leveling Benefits
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Why this training
Can you answer these questions:• What is the purpose of leveling?
• What are the three components of leveled production?
• How do we level production?
• What are the benefits of leveling?