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Lean and MTM – scientific, practical and educational perspectives to enhance productivity The Method Determines the Success Pole position in international competition through the consistent use of MTM across the process of product emergence. MTM Conference, Istanbul, 16. May 2014 © German MTM-Association 1 Lean and MTM – scientific, practical and educational perspectives to enhance productivity Prof. Dr. Peter Kuhlang, Head of MTM-Institute, German MTM-Association

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Generel explanation for MTM&IMD organization Was presented at MTM Turkey Conference im 16.05.2014 by Prof. Dr. Peter Kuhlang, Head of MTM-Institute

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  • Lean and MTM scientific, practical and educational perspectives to enhance productivity The Method Determines the Success Pole position in international competition through the consistent use of MTM across the process of product emergence. MTM Conference, Istanbul, 16. May 2014 German MTM-Association 1 Lean and MTM scientific, practical and educational perspectives to enhance productivity Prof. Dr. Peter Kuhlang, Head of MTM-Institute, German MTM-Association
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 2 Lean and MTM scientific, practical and educational perspectives to enhance productivity Agenda 1. Introduction Who we are 2. Lean thinking and MTM The mutual context and their relationship 3. Lean and MTM application examples Lean Production: Assembly of micro contactors Lean Logistics: Packing of spare parts 4. Preconditions and necessities to apply MTM Software and international standardised training programmes 5. Outlook MTM Productivity Management concept Industrial Engineering Handbook
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM-Organization MTM Conference, Istanbul, 16. May 2014 German MTM-Association 3 German MTM-Association German MTM-Company MTM do Brasil Sao Paulo MTM Polska Wrocaw MTM PSC USA Chicago MTM China Shanghai MTM India Chennai Academy Berlin, Stuttgart Institute Berlin, Zeuthen Association Hamburg Software Dresden Training Center Stuttgart Engineering Services Hamburg, Stuttgart Consulting Stuttgart Companies Abroad non-profitprofit
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 4 Overview about MTM MTM Methods-Time Measurement Instrumental: methodology Avoiding waste in value stream Information stream Material stream Value added Construction Planning Production Organizational development Organizational planning Organizational sequence Institutional: organization Non-profit associations / for profit consultancy
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity Lean-Toolbox MTM Conference, Istanbul, 16. May 2014 German MTM-Association 5 SMED More tools: Gemba Poka-Yoke DfMA Kata Andon Cardboard Eng. Structured in production systems WCM TPS
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity Return to Work Measurement Shigeyasu Sakamoto MTM Conference, Istanbul, 16. May 2014 German MTM-Association 6 Companies have to think about smart working methods rather than the trendy (sometimes impractical ways) methods Secret of productivity improvement: engineered standard time and labor performance control system IEs must follow a balance between maintaining a commitment to the basic traditional tools and rolling with the evolution For real productivity improvement it is sometimes better to return to traditional measurements instead of modern methods like Kaizen or Lean Management But there is no right or wrong way to improve the productivity Source: Industrial Engineer, member forum, Mar 2009; 41, 3; Docstoc pg. 24
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 7 Lean Thinking and MTM Applying Lean methods to identify and eliminate waste Productivity time (years)SOP Waste and non-value adding tasks Added value Work content Waste and non-value adding tasks Added value Added value identify and eliminate waste Source: Miller/Blockhus, 2005 ? Applying more, new, different Lean methods or/and approaches in broader scope Lean Logistics, Lean Layout Lean Engineering, Lean Administration Short-cyclic improvement process - Kata Intensify the understanding of processes/value streams view into work systems time determination MTM acts like a scale and defines productivity level 2 1 Waste and non-value adding tasks Added value Waste and non-value adding tasks Added value Added value identify and eliminate waste How to counteract the diminishing productivity progress?
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 8 Time vs. method focus Modeling of human work Plan and explore the optimal human operating point MTM provides a norm performance Work contet (time) Combination: Increase of intensity and improvement of processes Systematic modelling of processes based on process blocks Develop and apply standard processes Restrictions Current processes Focus : time Lean/CIP Ideal Target processes Focus: (work) method Systematic planning t
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 9 How to apply the MTM methodology Start: Assemble connection plug to compressor and tighten it to torque. MTM-Datacard (exc. of MTM-UAS Basic Operations) Distance (cm) 0 20 20 50 50 80 Get and Place AF1 (40 TMU) AF2 (65 TMU) AF3 (80 TMU) Handle Aid HB1 (40 TMU) HB2 (60 TMU) HB3 (75 TMU) Plan or observe operation Finish: Modelled standard operation incl. standard time (285 TMU 10s) Plug to thread AF2 165 651 Turn on ZA2 515 752 Torque wrench HB2 160 603 1. Turn ZA1 15 54 2.-3. Turn ZC1 230 605 285 Turn to torque ZD 120 206 Choose process blocs and model operation x Assemble connection plug D Z 7 0 5 . 0 5 . . . 5
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 10 MTM application the whole value streams Production planning PPC Dayly order daily Customer Assembly plant Cologne 18.400 Pcs./month 12.000 left 6.400 right 20 Pcs./container 2 shifts CT: 40s ST: 0 Reliability: 100% Assembly II 1200 le 640 ri 2d 40s Workers: 1 SC: 2 Shipping 2700 le 1440 ri 4,5T4,5d 23,6d 188s CT: 62s ST: 0 Reliability: 100% Assembly I 1600 le 850 ri 2,7d 62s Workers: 1 SC: 2 CT: 46s ST: 10min Reliability: 80% Spot welding II 1100 le 600 ri 1,8d 46s Workers: 1 SC: 2 CT: 39s ST: 10min Reliability: 100% Spot welding I 4600 le 2400 ri 7,6d 39s Workers: 1 SC: 2 CT: 1s ST: 1h Reliability: 85% Die cutting Steel coils 5 days 5d 1s Workers: 1 EPEI: 2 weeks Supplier Ruhr AG 90/60/30-day-forecast Tuesday and thursday Weekly order 6-Weeks-forecast Weekly planning Daily planning Flow of material & information Flow of information Incoming goods Work method Balancing Multiple workers and workplaces Setup times Intra-plant transport Shipping/ Packing/ Dispatching Operating times Added value Ergonomic work system design Informational work
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 11 Software support in productivity management MTMmobile for iPad
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 12 MTM educational concept (Germany) Internat. standardised educational levels: MTM-Practitioner MTM-Instructor Education programs for students: Basic-MTM (MTM-1 and UAS) MTM-Practitioner Prozessarchitecture Value Stream Mapping / Logistics Busines Process Management Design for Assembly: ProKon Productivity Management Lean Line Design MTM-Engineer 3 d 33 d 3 + 2 d 2 d 3 d 5 d 3 d Total: 54 d MTM-1 (part 1) MTM-SD MTM-UAS MTM-MEK MTM-Practitioner-Semianr or or MTM-Practitioner-Diploma MTM-2 or 5 d MTM-Practit.-Homework/Thesis 5 d Duration of training: 33 d EAWS 5 d 8 d MTM-1 (part 2) or
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity COD. COURSE TITLE Unit of measure MinDuration RecommendedDuration MTM-1 MTM-2 SAM MTM-UAS MTM-MEK EAWS PROKON MTMTRAINER EAWSTRAINER MTMINSTRUCTOR EXAM+CERTIFICATION TESTIMONIALCERTIFICATE BLUECARD GREENCARD GROUND COURSES G01 INTRODUCTION TO WORK ANALYSIS days 2 3 X G02 MTM BASE (1) days 3 3 X CERTIFICATE LEVEL - FUNDAMENTAL SPECIALISTIC COURSES F01 MTM-1 days 10 15 X F02 MTM-2 days 5 5 X F04 SAM days 5 5 X F05 MTM-UAS days 5 5 X F06 MTM-MEK days 4 5 X F07 EAWS days 5 8 X F08 PROKON days 2 3 X MTM-PRACTITIONER LEVEL P01 SHOP FLOOR TUTORSHIP (per technique) days 5 10 P02 EVIDENCE OF COMPETENCE IN PRACTICAL APPLICATION evaluation - X MTM-INSTRUCTOR LEVEL I01 INSTRUCTOR COURSE days 3 5 X I02 PROJECT EXPERIENCE months 6 36 I03 TEACHING EXPERIENCE course - 1 X I04 PROJECT WORK PRESENTATION days 1 1 X IEX EXAMINATION days 1 1 X X MANDATORY RECOMMENDED Recognized Qualification: 1choice LICENSECERTIFINSTRUCTOR 1choice PRACTITIONER MTM Conference, Istanbul, 16. May 2014 German MTM-Association 13 International standardised educational levels Source: IMD, Code of Practice, 2014
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity Global footprint of MTM MTM a reliable measure in science, practice & training MTM Conference, Istanbul, 16. May 2014 German MTM-Association 14 The work from mens perspective. The process, or rather the optimal method determines the time. There are limits (e.g. utilization) but this transparency is necessary. A fair measure of performance Work at an optimal level. Work smarter, not harder! Trust Responsibility Fairness Sense
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity Understanding MTM: Industrial Engineering Handbook MTM Conference, Istanbul, 16. May 2014 German MTM-Association 15 Productivity SOP ? 2 1 COD. COURSE TITLE Unit of measure MinDuration RecommendedDuration MTM-1 MTM-2 SAM MTM-UAS MTM-MEK EAWS PROKON MTMTRAINER EAWSTRAINER MTMINSTRUCTOR EXAM+CERTIFICATION TESTIMONIALCERTIFICATE BLUECARD GREENCARD GROUND COURSES G01 INTRODUCTION TO WORK ANALYSIS days 2 3 X G02 MTM BASE (1) days 3 3 X CERTIFICATE LEVEL - FUNDAMENTAL SPECIALISTIC COURSES F01 MTM-1 days 10 15 X F02 MTM-2 days 5 5 X F04 SAM days 5 5 X F05 MTM-UAS days 5 5 X F06 MTM-MEK days 4 5 X F07 EAWS days 5 8 X F08 PROKON days 2 3 X MTM-PRACTITIONER LEVEL P01 SHOP FLOOR TUTORSHIP (per technique) days 5 10 P02 EVIDENCE OF COMPETENCE IN PRACTICAL APPLICATION evaluation - X MTM-INSTRUCTOR LEVEL I01 INSTRUCTOR COURSE days 3 5 X I02 PROJECT EXPERIENCE months 6 36 I03 TEACHING EXPERIENCE course - 1 X I04 PROJECT WORK PRESENTATION days 1 1 X IEX EXAMINATION days 1 1 X X MANDATORY RECOMMENDED Recognized Qualification: 1choice LICENSECERTIFINSTRUCTOR 1choice PRACTITIONERProduction planning PPC Dayly order daily Customer Assembly plant Cologne 18.400 Pcs./month 12.000 left 6.400 right 20 Pcs./container 2 shifts CT: 40s ST: 0 Reliability: 100% Assembly II 1200 le 640 ri 2d 40s Workers: 1 SC: 2 Shipping 2700 le 1440 ri 4,5T4,5d 23,6d 188s CT: 62s ST: 0 Reliability: 100% Assembly I 1600 le 850 ri 2,7d 62s Workers: 1 SC: 2 CT: 46s ST: 10min Reliability: 80% Spot welding II 1100 le 600 ri 1,8d 46s Workers: 1 SC: 2 CT: 39s ST: 10min Reliability: 100% Spot welding I 4600 le 2400 ri 7,6d 39s Workers: 1 SC: 2 CT: 1s ST: 1h Reliability: 85% Die cutting Steel coils 5 days 5d 1s Workers: 1 EPEI: 2 weeks Supplier Ruhr AG 90/60/30-day-forecast Tuesday and thursday Weekly order 6-Weeks-forecast Weekly planning Daily planning Flow of material & information Flow of information Incoming goods Work method Balancing Multiple workers and workplaces Setup times Intra-plant transport Shipping/ Packing/ Dispatching Operating times Added value Ergonomic work system design Informational work Productivity Management by MTM Prevention Sustainability Design evaluation (Value analysis, QFD) Assembly oriented product design (ProKon) Technical calculation Supply and actualise bill of activities/work plan with target times Task analysis and synthesis, task relevance analysis Process analysis and documentation (Flow charts, table visualisation) Process modelling and improv. with MTM process building block systems Supplementary techniques (estimate, standard data, process time eval) Layout planning Ergonomic Assessment Planning and implementing of work systems Ramp-up & shop floor management Supplementary techniques (self-recording, time measurment, work sampling,) Target time analysis and synthesis (target and lead times) Value Stream Mapping Company-specific building block systems / target time management Personnel requirement planning and controlling Improvement management (labor) time management Renumeration differentiation Project management 1.Product development 2.Process development 3.Operation & improvement Source: Bokranz/Landau, 2012
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity MTM Conference, Istanbul, 16. May 2014 German MTM-Association 16 Industrial Engineering - Can you imagine it? If it moves, its Mechanical. If it doesnt, its Civil. If it smells, its Chemical. If it is invisible, its Electrical. And if you cant even imagine it, its INDUSTRIAL! [Oren] MTM-Methods for Product Engineering and anticipative Industrial Engineering MTM-Methods for corrective Industrial Engineering Design and development support Planning, operations and improvement support Productivity Management of Work Systems with MTM-Methods 1.Product development 2.Process development 3.Operation & improvement SOP Productivity Ramp Up Productivity progression with MTM higher productivity at SOP steep rise of productivity after SOP
  • Lean and MTM scientific, practical and educational perspectives to enhance productivity Productivity Management by MTMPrevention Sustainability Design evaluation (Value analysis, QFD) Assembly oriented product design (ProKon) Technical calculation Supply and actualise bill of activities/work plan with target times Task analysis and synthesis, task relevance analysis Process analysis and documentation (Flow charts, table visualisation) Process modelling and improv. with MTM process building block systems Supplementary techniques (estimate, standard data, process time eval) Layout planning Ergonomic Assessment Planning and implementing of work systems Ramp-up & shop floor management Supplementary techniques (self-recording, time measurment, work sampling,) Target time analysis and synthesis (target and lead times) Value Stream Mapping Company-specific building block systems / target time management Personnel requirement planning and controlling Improvement management (labor) time management Renumeration differentiation Project management 1.Product development 2.Process development 3.Operation & improvement Source: Bokranz/Landau, 2012 MTM Conference, Istanbul, 16. May 2014 German MTM-Association 17 looking forward to answering your questions! Contact: Prof. Dr. Peter Kuhlang Head of MTM-Institute German MTM-Association MTM-Institute Eichenallee 11 15738 Zeuthen Germany Tel.: +49 33762 20 66-31 Fax: +49 33762 20 66-40 Mobil: +49 151 4225 1234 [email protected] www.dmtm.com