lean manufacturing line demonstration this short powerpoint presentation is designed to give the...
TRANSCRIPT
Lean Manufacturing Line Demonstration
This short PowerPoint presentation is designed to give the reader an example of how a Lean/Pull system operates. It demonstrates how a process, (i.e final assembly) is divided into individual workstations equal to a TAKT time. This causes the work in a process to be balanced where all workstations complete the standard work at the same time. TAKT time is a statement of rate calculated as the available time per day divided by the designed volume of the process. Even though standard work time may vary from process to process and product to product, one complete unit is finished each TAKT time.
Because all processes are completed simultaneously, no work in process inventory is accumulated between processes. Customer lead time is the sum of the TAKT times through the critical path processes of the Lean line. Priority changes in customer demand are easily facilitated by rearranging the sequence of demand introduced to the lean line on any given day.
Customers rarely order the same volume of demand every day. Matching labor resources to customer demand each day avoids building unsold finished goods inventory. Operator job satisfaction is enhanced by being allowed to be flexible to do different work every day as
needed.
Please enjoy viewing this presentation. Review as often as necessary to re-enforce your knowledge of how a Lean/Pull system works. Consider how a Lean manufacturing operating system delivers the critical differentials in price, delivery, and quality to give you the leverage you need to capture market share from your competitors.
Please contact Dennis Hobbs at Mfg Matters if you have questions about this presentation or any other questions you may have about a Lean business transformation.
Sequenced Build – First in – First Out at TAKT Rate Mixed Model Production
Two Bin Material Kanban System
No Work-Center Schedule – Respond to TAKT Signal
Build-to-Order Production – No WIP Build up
Production Sequencing to Match Demand Priority
Output Rate Variation Based On Daily Demand
Flexible EmployeesTakt 1 Takt 2 Takt 3 Takt 4 Takt 5
X
S/OS/OS/OSALESORDER
What To Look For
Empty IPKProduct
75% completeProduct
50% completeProduct
25% complete
WS 1 WS 2 WS3 WS4
Empty Workstation
WS 1 WS 2 WS3 WS4
Primary Bin
Secondary Bin
WS 1 WS 2 WS3 WS4
Is the signal to pullthis unit into
this Workstation
This emptyIPK
WS 1 WS 2 WS3 WS4
Causing this IPKto be empty
Then, this unitis pulled
WS 1 WS 2 WS3 WS4
And materialsare consumed
WS 1 WS 2 WS3 WS4
WS 1 WS 2 WS3 WS4
Product100% complete
WS 1 WS 2 WS3 WS4
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
S/OS/O
S/OSALESORDER
WS 1 WS 2 WS3 WS4
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
S/OS/O
S/O
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
S/O
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
S/O
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
S/O
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/OS/O
Notice that the fourth cycle did not result in a product
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/O
Supermarket
Takt 1 Takt 2 Takt 3 Takt 4 Takt 5
WS 1 WS 2 WS3 WS4
S/O
Supermarket
Sequenced Build – First in – First Out at TAKT Rate Mixed Model Production
Two Bin Material Kanban System
No Work-Center Schedule – Respond to TAKT Signal
Build-to-Order Production – No WIP Build up
Production Sequencing to Match Demand Priority
Output Rate Variation Based On Daily Demand
Flexible EmployeesTakt 1 Takt 2 Takt 3 Takt 4 Takt 5
X
S/OS/OS/OSALESORDER
Did You Observe-?