poka yoke mapping - panyapiwat

1

Poka Yoke Mapping

Plan For Every Part

PFEP & Poka Yoke Mapping

2

รายละเอยดการฝกอบรม

09.00-10.00 น. การปองกนความผดพลาด ( Error Proofing )

Poka Yoke Mapping

Workshop

13.00-16.30 น. Continuous Flow

Plan For Each Station ( PFES ) & Plan For Every Part ( PFEP )

Central Supermarket

Workshop

3

Error Proof

Error Proof Mapping

การปองกนความผดพลาด

4

Error Proof

คณเคยท าผดพลาดบางไหม ?

5

ขอจ ากดของมนษย

• คนท างานอยางมสมาธตอเนองไดประมาณ 15 นาท • คนเราไมรสกตวหากถกแทรก เชน ระหวางท างานมคนมาเรยกท าใหลม

• หากมขวญก าลงใจด สมาธกจะด ท างานไดอยางตอเนอง

• ถามอะไรไมถกใจ หรอ มเรองกลมใจสมาธจะสน

• ขอบเขตทสายตาไปถงจะเปนขอบเขตของสมาธ หากเกนไปหรอมองไมจะ

หมดสมาธ

• การทจะใหคนงานท างานเกนขอบเขต แตใหมสมาธดๆ นนเปนไปไดยาก

• สรป ตองเขาใจจดออนคนเพอทจะใช Poka Yoke ใหถกตองมากขน

6

ความนาเชอถอในตวมนษยม 5 ระดบ

ระดบท 0 : ไมมสตเลย เชน นอนหลบ อาการชก ระดบท 1 : เหมอลอย เชน เวลาเมา ลา ท างานทซ าซาก ไมมความรสกเตอน

ตวเอง ระดบท 2 : สมาธระดบธรรมดา เชน ท างานทวไป ระหวางพก ระดบท 3 : สมาธระดบปกต เชน ท างานไดอยางกระตอรอลน มสตท างานให

ด มความรสกระวงตวเองเตอนตวเองได ระดบท 4 : สมาธระดบด ท างานรบๆ ได แตมนจะตรงเกนไป

7

ชนดของความผดพลาดจากมนษย

1 : ลม 2 : เขาใจผด 3 : ไมมประสบการณ 4 : แกลงท าผด 5. รางกายรบไมได เหนอยลา

8

ของเสยเปนศนย 100% ตลอดเวลา

สรางสงแวดลอมการท างานทปราศจากของเสย

ใชสตปญญามนสมอง ความคดสรางสรรคท างานของคณใหไมมของเสย 100% ตลอดเวลา

Poka-Yoke

10

อนไหนเกลอ

11

จะปองกนการผดพลาดไดอยางไร

อะไรบางทอาจกอใหเกดโอกาสในการท าผดพลาด จะปองกนมนไดอยางไร

12

Does

100%

Inspection

Finds

100% of

the Rejects

100% of

the Time?

FINISHED FILES ARE THE RE-

SULT OF YEARS OF SCIENTIF-

IC STUDY COMBINED WITH

THE EXPERIENCE OF YEARS.

ใหนบตวอกษร F ในหนากระดาษน

Exercise

ปรชญาของ Poka Yoke

• พงระลกไวเสมอคน เครองจกร และกระบวนการท างานผดพลาดได

• ขจดการตดสนใจ ประเภทกะ ประมาณ เดา ลองผดลองถก ของพนกงานออกไป

• ใชความคดแบบสรางสรรค และงายๆ ในการเอาชนะความผดพลาดขอ

มนษยและกลไก

• อยายอมรบวาสาเหตเกดจากความผดพลาดของพนกงาน

• ตงมาตรฐานของเสยเปนศนย

• ตงเปาหมายของเสยเปนศนยถอเปนความรบผดชอบของทกคน

15

ค าจ ากดความของ “ความผดพลาด (Error)”

ความผดพลาดคอสงเบยงเบนใดๆไปจาก

ขบวนการทควรเปนหรอตงเปาหมายไว

ความผดพลาดคออะไร ?

16

WHAT IS THE DIFFERENCE

BETWEEN

PREVENTION &

DETECTION?

17

PREVENTION DETECTION

18

OUR EFFORTS SHOULD FOCUSON THE

MISTAKE STAGE

Mistake

Detect Mistake

Correct Mistake

Produce Parts

Produce Parts Detect Defect

Fix Part

Eliminate Cause

19

ควบคมและตรวจสอบ

Process

Control Inspect

Process

characteristics

Product

characteristics

Level 1 : Identify cause of the defect

Level 2 : detect the defects

Level 3 : prevent the impossible error

20

Find the problems Good

Wrong

To the

Client

Quality control

Production flow

Repair / Reject

Solve the problems

Avoid / Prevent

problems

To the

Client R & D

Quality control

Repair / Reject Repair / Reject

Poka Yoke

1.

2.

3.

To the Client

Control & Inspect

21

WHEN A DEFECT

IS ABOUT TO OCCUR HAS OCCURRED

MISTAKE-PROOF

DEVICE

MISTAKE-PROOF DEVICE

WARNING

SIGNALS MISTAKE

IS ABOUT TO

OCCUR

CONTROL

EVEN INTENTIONAL

ERRORS ARE

IMPOSSIBLE

SHUTDOWN

OPERATIONS

STOP WHEN

DEFECT PREDICTED

WARNING SIGNALS

DEFECT HAS

OCCURRED

CONTROL

DEFECTIVE PARTS

CAN NOT PASS ON

SHUTDOWN

OPERATIONS

STOP WHEN

DEFECT DETECTED

22

การปองกนความผดพลาดคออะไร?

คอระบบการปรบปรงพฒนากระบวนการ เพอลดโอกาสในการเกด ความผดพลาดและลดคาใชจายในการจดการความผดพลาดทเกดขน การปองกนความผดพลาดเปนหนงในเครองมอทมอยซงจะชวย ใหเราไปถงเปาหมายของการผลตงานอยางไมมขอบกพรอง พฒนาโดย Shigeo Shingo

ปองกนการบาดเจบของผปฏบตงาน ปองกนความผดพลาดในการผลตงาน ลดกจกรรมทไมกอใหเกดคณคาเพม ทสดของการปองกนความผดพลาด คอ เอาคนตาบอดมาท ากไมผดพลาด

23

ความผดพลาดสามารถเกดขนไดเมอเงอนไขทจ าเปนของขบวนการผลตด าเนนไป อยางไมสมบรณหรอขาดหายไป

ขอบกพรอง (Defect) ทงหลายเกดขนไดโดยความผดพลาด (Error)

ไมใชความผดพลาด (Error) ทงหมดจะกอใหเกดขอบกพรอง (Defect) เสมอไป

ขบวนการถดไป ความผดพลาด ขอบกพรอง ทอาจเปนไปได ขบวนการกอนหนาน

ขนตอนในขบวนการผลตปจจบน

ค าจ ากดความของ “ความผดพลาด (Error)”

ตวอยาง Poka Yoke ในชวตประจ าวน

30

ประเภทของความผดพลาดจากความไมระมดระวง

1. แปรรปผด 2. ประกอบผด 3. จ านวนผด 4. ประกอบไมครบ 5. เดนเครองผด 6. เตรยมงานผด 7. สงแปลกปลอมเจอปน

31

ประเภทของ Poka Yoke

1. Poka Yoke จ านวน เชนเบกของตองครบ 2. Poka Yoke น าหนก เชน น าหนกไมได เครองไมท างาน เกนหรอขาด

เครองจะรอง 3. Poka Yoke ความยาว เชน สงเกนมาตรฐานจะม alarm สนเกนจะม

alarm

4. Poka Yoke รปทรง เชนลกษณะพเศษของตวชนงาน 5. Poka Yoke การประสานงานกนระหวางคนกบเครองจกร เชน ล าดบชน

ของการท างาน หากขามขนตอนเครองจกรจะไมท างาน 6. Poka Yoke ขอบเขต เชน limit ของแรงดนกาซ 7. Poka Yoke ล าดบการท างานของ WI ( Work Instruction )

32

กลไก Poka Yoke

1. หากมของเสยเครองจกรจะไมแปรรป 2. หากมการปฎบตงานผดพลาด ชนงานไมสามารถเขาไปในจกได 3. หากมการท างานผดพลาด เครองจะท าการแกไขและแปรรปไดอยางถกตอง 4. คนพบของเสยของกระบวนการกอนหนา เครองจะหยดไดเองโดยอตโนมต 5. คนพบการลมท างานของกระบวนการกอนหนา เครองจะหยดท างานทนท

33

ความผดพลาดและขอบกพรอง

ความผดพลาด ขอบกพรอง สภาพทท าใหเกด

ใสเกลอแทนทจะเปน น าตาล

มเกลอในกาแฟ •ทบรรจเหมอนกน

•ความเมอยลาของพนกงาน •อานหนงสอหรอท าอยางอน อยดวย

การก าหนด ความเรวของเครองผด

ชนสวนตาง ๆทผลต ไมไดตามขอก าหนด

• WI เขยนไวไมสมบรณ

• P/N เหมอนกนมาก • การฝกอบรมผปฏบตงาน

• ความยากในการใชเครอง

34

Build a Culture of Stopping to Fix Problem, to Get Quality Right the First Time

Error-proofing

Problem solving

Response system

Building culture of stopping to fix problem

35

Error Proof – Response System

Team members are empowered to stop machines or the entire production line if a problem occurs. Mistake-proof devices ensure that defects will be caught and corrected before unacceptable products are produced.

Response system Error – proofing (poka yoke)

Approach for operators:

Preventative

If trouble, Stop!

If defective don’t pass

Immediate response from support areas

Approach for machines:

A mistake-proofing system prevents errors and defects

Stop line when defects are detected or machines break down

STOP

Trouble!

Poka-yoke

STOP

36

การปองกนความผดพลาด : ชนดของความผดพลาด

1. Processing omissions: การท างานขามขนตอน

2. Processing errors: การไมท างานตามขนตอนมาตรฐานการท างาน

3. Error in setting up the work piece: ใชเครองมอไมถกตองหรอ ปรบแตงเครองมอไมตรงกบผลตภณฑทก าลงท า

4. Missing parts: ใสชนงานทตองการในการประกอบ/เชอมไมครบ

5. Improper part/item: ใสชนงานทไมถกตองเขาไปในการประกอบ

ความผดพลาด (Error) 10 ประการทสามารถใช Error Proofing ชวยในการแกไขหรอก าจดใหหมดไป

37

6. Processing wrong workpiece: ท างานทไมตองการใช

7. Operations errors: ท างานไมตรงตามขอก าหนดปจจบน ซงอาจเกดจากการใช Spec ทไมถกตอง (ผด Revision)

8. Adjustment, measurement, dimension errors: ความผดพลาดจากการปรบแตง,ทดสอบเครองหรอวดขนาดชนงานจากการกระท า ของผสงมอบงาน(supplier)

9. Errors in equipment maintenance or repair: ขอบกพรองจากการซอมหรอเปลยนชนสวนของเครองมอไมถกตอง

10. Error in preparation of consumables: การเตรยมตวในการผลตไมถกตองเชน Tool ทออกแบบไมเหมาะกบการท างาน, อณหภม ท Set ไมถกตอง

การปองกนความผดพลาด : ชนดของความผดพลาด

38

หลกการใชลดความนาจะเปน ในการเกดความผดพลาดของคนมดงน

การปองกนความผดพลาดจากคน

1. ท าใหเหนไดชดเจนดวยตา 2. ระบคนรบผดชอบ 3. จดหากลไกการใหขอมลปอนกลบเขาไปในการควบคม 4. จดท าขอจ ากดของเครองมอการปฏบตงาน

จ ากดดวยวตถ

จ ากดดวยการเรยนร 5. จดท าเปนมาตรฐาน

Types of Mistake- Proof Devices

• Guide/reference/interference rod or pin*

• Alarm*

• Limit switch/ microswitch*

• Counter*

• Checklist*

• Template

• Odd-part-out method

• Sequence restriction

• Standardize and solve

• Critical condition indicator

• Stopper/gate

• Sensor

• Detect delivery chute

* Most commonly used

40

ท าใหเหนไดดวยสายตา

มปายบอก

ใชเสยงเตอนใหชดเจน

เปานกหวด

ใสเครองหมาย/สญญานเตอนของการหยดการท างาน

การท าใหพนกงานเหน สมผส รบรสภาพของการท างาน, ขอมลปอนกลบการท างาน และผลกระทบจากการปฏบตงานของแตละคน

41

จดท าขอจ ากด

จ ากดดวยลกษณะวตถ

จ ากดดวยการเรยนร

42 42

Error Proofing Devices (1)

Work-Piece

Platform

Locating Pins

Locating Pins

เพอใหมนใจไดวาชนงานวางถกต าแหนง

43 43

Profiler Cutting Wheel

offset is fixed

Template Work-Piece


Templates

เพอใหมนใจไดวาชนงานถกท าตามตนแบบไมมผดเพยน

44 44


Limit Switches

เพอใหมนใจไดวาความลกในการตดหรอเจาะไดขนาดทสม าเสมอ

Cutting Tool

Work-Piece

Limit Switches

45 45

Critical Condition Indicator

บงชวาคาของตวแปรตางอยในขอบเขตทก าหนด


Guide/Reference/ Interference Rod

Rods Rod Clearance Area

Example:

Alarms

Fire Alarm

Car Alarm

Christmas Tree lights on machine

Limit Switch or Microswitch

The grooved edges of two sides of the work pieces are

used as guides for setting up the plates correctly. A limit

switch is mounted on the jig and interlocked with the start

switch so it is impossible to start the drill press if the side

plate is set in the wrong position. Defects due to defective

holes are completely eliminated.

Example:

49

An indicator that keeps track of the number of:

parts, turns, strokes, output, or abnormalities.

Can be mechanical or electronic.

8 4

Counter

Example:

50

Checklist

• Preflight pilot

checklist

• “To Do” lists

• Inspection checklists

51

Made of sheet metal. Has configuration to

guarantee accurate positioning.

0 +1

2

3

-

456

5

4

3

21

BASIC

-1

-2+5

+4

+3

+2 +1

Template

Example:

52

Supply only the correct number of parts.

When the operation is complete there

should be no left over parts or shortages.

ASSEMBLY

DETAILS

Odd Part Out

Example:

Sequence Restriction

Example

A new “first-in, first-out” rack was developed that dispenses the tapes

only in the proper order for testing. When one tape is removed for

use, the next tape slides down, ready for use. When a tape has been

used, the inspector places it in the top of the rack, where it remains in

the correct order. Errors in the testing sequence are completely

eliminated.

Standardize and Solve

Example

The containers are packed on a scale. If there are too

few gears in a box, it will not weigh enough, and the

omission is detected.

55

Critical Condition Indicator

Min

Max

Normal

Pressure

Pressure

Gauge

Normal Direction of

Motor Rotation

Normal Direction of Fluid

Circulation

Oil Tank Cap

Mobil DTE 25

Max

Min

Sight Glass

Normal

Fluid Level

56

Sensor

Tempilabel Temperature

Monitor ®

77° C 82° C 88° C 93° C

A N

o. 4

A-1

70

/77

170° F 180° F 190° F 200° F

Center Turns Black at Rating Shown So.

Pla

infield

, N

J, U

.S.A

.

Example

Delivery (Detect) Chute

Example

Using the fact that the unwelded bushing is missing the shaft,

a mechanical sorter was developed to remove the faulty

parts from the transport line.

sorting arm

chute

good items unwelded

bushings

sorting arm

from automatic welding machine

chute

retrieval bin

to next

process

58

EXAMPLE OF SOLUTION OTHER THAN DEVICE

REDESIGN

MUST TALK WITH THE

DESIGN ENGINEER AND

LET THEM KNOW THAT THE

PROBLEM CAN BE SOLVED

BY REDESIGNING THE

PARTS, TOOL, OR MACHINE

PART # ELIMINATED

Successful Mistake- Proof Devices

You should be able to answer yes to all of these:

• Is it safe to use?

• Prevents reoccurrence?

• Inexpensive?

• Simple to use?

• Easy to implement?

• Durable?

• Easy to maintain?

• Does not hinder operator?

• Gives prompt feedback?

• Gives prompt action (prevention)?

• Has the right people’s input?

• Reliable—does not give false signals?

60

Exercise: Mistake Proofing

• Step 1: Read the “Before Improvement” section for the

mistake proofing scenario assigned to your team.

• Step 2: Work with your team members to identify

potential mistake-proofing applications for each problem

assigned.

• Step 3: In the “After Improvement” section, describe the

mistake-proofing device that you feel would over come

the problem. Include sketches. Prove as many devices

as possible during the allotted time frame.

• Step 4: Prepare a presentation of you team’s ideas.

Description of Process: Small sign plaques are mounted on a panel.

Before Improvement:

Although the workers were careful when

mounting the plaques, defects occurred

because it was possible to mount them

upside down.

After Improvement:

Process: Mounting small plaques on a panel Problem: Plaques mounted upside down

Description of Process: Molded items are milled in an automatic machine and delivered to

the next process via a chute.

Before Improvement:

If an unmilled part came through the chute,

the next machine shut down abnormally and

could be damaged.

After Improvement:

Process: Milling molded items Problem: Unprocessed items


Description of Process: A chassis was placed in a jig for machining.

Before Improvement:

It was possible to insert the chassis

in the jig backwards. Correct

operation depended on the worker’s

vigilance.

After Improvement:

Process: Processing chassis Problem: Chassis set backwards in jig


Description of Process: Four mounting holes are drilled in many different

types of plates. The holes are all equally spaced in one dimension, but are

spaced differently along the other axis, depending on the size of the plate.

Before Improvement:

The holes were drilled with a four-

spindle drill press, which required

setup for each different type of plate.

When the number of types of plates

increased, time required for setup

increased as well, and setup errors

increased in incorrectly drilled holes.

After Improvement:

Process: Drilling a variety of

different work pieces

Problem: Errors made during setup for



Description of Process: Four mounting holes are drilled in many different

types of plates. The holes are all equally spaced in one dimension, but are

spaced differently along the other axis, depending on the size of the plate.

Before Improvement:

The holes were drilled with a four-

spindle drill press, which required

setup for each different type of plate.

When the number of types of plates

increased, time required for setup

increased as well, and setup errors

increased in incorrectly drilled holes.

After Improvement:






A new method for drilling the mounting

plates was developed that makes setup

operations unnecessary and completely

eliminates defects in hole spacing. A

two-spindle drill press is set to the

constant hole spacing used in all the

plates. A stop block is located on the

drill press table in line with the spindles,

and the jigs for the different plates now

have notches at each hole position. The

block fits into the notch in the jig as

each plate is fed in. It is now possible to

continuously feed the work pieces and

position them accurately.

Description of Process: Four mounting holes are drilled in many different types of plates. The holes are

all equally spaced in one dimension, but are spaced differently along the other axis, depending on the size

of the plate.

Before Improvement: After Improvement:






Description of Process: Cables of many different sizes and colors are wired to a multipoint terminal

board.

Before Improvement:

The workers followed a diagram mounted over

the terminal board. Defects occurred because of

misunderstandings, mix-ups, or oversights made

when workers looked from the diagram to the

wiring work.

After Improvement:

Process: Wiring terminal boards Problem: Wiring errors


Description of Process: Cables of many different sizes and colors are wired to a multipoint terminal

board.

Before Improvement:

The workers followed a diagram mounted over

the terminal board. Defects occurred because of

misunderstandings, mix-ups, or oversights made

when workers looked from the diagram to the

wiring work.

After Improvement:

Process: Wiring terminal boards Problem: Wiring errors


A wiring template was made that slides between the

rows of terminals on the board. Samples of the

correct wire for each terminal are attached to the

template, and the worker can tell at a glance which

terminal to connect with a particular wire.

72

Front Seat Process Flow

1 2

Receive Part from supplier

Incoming Inspection

3 Picking all parts

Load frame structure to

build pallet/Install silencer 4

5

6

Install back's foam to frame structure

Close out trim to Front Back

8 Install front cushion +

pan to frame structure 7

Load Cushion Foam to Pan

Close out trim to Cushion

10

9

11

12

Install plastic part

Install buckle Head Rest Sub-assembly

Install Head Rest

14 Steam

14 Final Inspection

15 Functional Checking

Plastic bag covering

16 Loading to Shipping Rack

17

18

Dock Audit

Ship to Customer

13 Install SAB

73

Opn#1

Load frame

Ergonomic

Lifter

Opn#2

Install B/F

Opn#3

Close Out

Cushion

Sub-Assy

Opn#4

Install Cushion

M8 X 2

Opn#5

Install Cushion

M8 X 2

Opn#6

Install Plastic

Opn#7

Install H/R

Arm Rest H/R

Sub-Assy

Opn#9

Steam

Opn#11

Final Inspect

Ergonomic

Lifter

Poka Yoke Mapping :

../../nnanthagasigorn/Local Settings/Temporary Internet Files/Temporary Internet Files/Temporary Internet Files/OLK80A/VIDEOS/03.- BALANCIN DE RINES.mpg

74

Poka Yoke Mapping :

Operation

Description #1 #2 #3 #4 #5 #6 #7 # 8 #9 #10 #11 Rwk C/S H/R

Monitor

Touch Screen Monitor

Bar Code Scanner

Bar Code Printer

LPS Software

Poka Yoke Lighting

PLC Program + Wiring

ToolNet

Prevent for wrong part

Prevent for no torque

Prevent for wrong bolt

As of Aug 13’2009

Off-Line

75

Poka Yoke Mapping Exercise

1 2


Incoming Inspection

3 Picking all parts



5

6







10

9

11

12



Install Head Rest

14 Steam

14 Final Inspection




17

18

Dock Audit

Ship to Customer

13 Install SAB

76

System Architecture

Three Tier Architecture

Application Business Logic

D/B

Server

D/B Management Software

SQL or Oracle

Helios 17”

Thin Client

For all scanners E

T

H

E

R

N

E

T

N

E

T

W

O

R

K

Automated Equipment (e.g. PLC’s)

Robotics

Data Collection (e.g. Barcode/RF Readers)

Atlas Copco

Remote I/O

Application

Server

77

Poka Yoke Mapping Exercise:

Description ตวอยาง

Defect

ผาไหม

Error Condition

( Cause of defect )

ลมถอดปลก

Type of solution

79

Continuous Flow

ไหลอยางตอเนอง

ไหลอยางตอเนอง

ประโยชนจากการผลตทละชน

1: Improves safety.

2: Builds in Quality.

3: Improves Flexibility.

4: Improves scalability.

5: Reduces inventory. cash is king.

6: Improves productivity.

7: Simplifies material replenishment.

8: Frees up floor space.

9: Makes kaizen take root.

10: Improves morale.

http://lssacademy.com/2008/02/07/long-live-the-king-cash/

ตวอยางการผลตทละชนได

แบบฝกหด : ท าไมจงไมสามารถผลตทละชนได

87

Plan For Every Part

Poka Yoke Mapping

PFEP & Poka Yoke Mapping

ขนตอนท 1 : Takt Time

ขนตอนท 2 : Operation sequence & Actual Cycle Time & Layout

ขนตอนท 3 : Poka Yoke Mapping

ขนตอนท 4 : PFEP

ขนตอนท 5 : Supermarket ( Shopping Area )

ขนตอนท 6 : Routing : ( Water Spider )

5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง

ขนตอนท 1 : : Takt Time


Elements of Flow

Takt

Time

Takt Time X Units in Process

=Manufacturing Cycle Time

Elements of Flow

1 sec

/unit

1 sec/unit X 10 units=

10 sec

Elements of Flow

Takt

Time

Takt Time is the same but the

number of units in process is

less so Lead-Time is less

Takt Time calculation

Personal Fatigue and Delay

94

Workcell Design

ขนตอนท 2 : Operation Sequence &

Cycle time & Layout


96

1 2


Incoming Inspection

3 Insert Battery to Body

Assy Lighting + Body 4

6 Reflector Sub-Assy

7 Len Sub-Assy

5 Plastic Cover + Pack

8

Reflector + Lean Sub-Assy

9 Ship

Process Flow

Takt Time = 3.00 Seconds

97

Exercise

1 2


Incoming Inspection

3 Insert Battery to Body 50 TMU

Assy Lighting + Body 80 TMU

4

6 Reflector Sub-Assy 108 TMU

7 Len Sub-Assy 38 TMU

5 Plastic Cover + Pack

8

Reflector + Lean Sub-Assy 40 TMU

9 Ship 50

80

38

108

40

0

20

40

60

80

100

120

Battery + Body Body Kit +

Refector + Len

Kit

Len + Frame Bulb + Reflector

+ Cap

Refector Kit +

Len Kit

1 2 3 4 5

98

Front Seat Process Flow

1 2


Incoming Inspection

3 Picking all parts



5

6







10

9

11

12



Install Head Rest

14 Steam

14 Final Inspection




17

18

Dock Audit

Ship to Customer

13 Install SAB

Cy

cle

Tim

e in

Se

co

nd

s

1 2 3 4 5 6 7 8 9 10 11 12 13

Takt

Time X 60 Sec.

Required

Manning Operators

Optimal

Manning Operators

Operators

Available Production Minutes

Takt Time

Customer Requirements

Sum of Manual & Walk Times

Takt Time

Sum of Manual Cycle Times

Cycle Times vs. Takt Time Percent Loading Bar Chart

450 240

1.875 112.5

150

140

130

120

110

100

90

80

70

60

50

40

30

20 32

97.0

27

55 73

61 57 53 67

105 120

75

12

X 60

450 240

1.875 112.5

150

140

130

120

110

100

90

80

70

60

50

40

30

20

67

112.5

Example

Process Layout Product Layout

Customer Focused/ModuleTeams/Business Units

Reduce WIP

Simpler Material Flow

Condensed Bills and Routings

Fewer Data Collection Points

Process vs.Product Layout

Traditionally the efficiency of individual operations was

considered more important than moving the product through

the total production process.

Workcell Design

กระบวนการผลตทไหลซบซอน

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

ขนตอนการผลตไหลสลบไปสลบมาท าใหเกด Stagnation Time

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

ขนตอนการผลตไหลไดในทศทางทเปนเสนตรง Stagnation Time มนอย

กระบวนการผลตทไหลไมซบซอน

U- cell / Linear Integration

U- cell / Linear Integration

U- cell / Ideal

Linear Ideal

High

Low

High Low

Varia

nces

Volume

Typical

Lean

Linear – U-cell Integration

LOAD

ENTRY

Lin

ear L

ine

1

4

2

3

5

6

7

Integrated U-shape cell with Linear

Back Frame sub-assembly

105

Right – Sized Equipment / Machine

Large Machine Small

Machine

Small

Machine

Small

Machine

106

Capital Management

Product A

Time

Capacity, Cost

Large Machine

Small Machine

Operation : Work Cell & Ownership concept

108

Operation : Work Cell & Ownership concept

Proposed Design

IN OUT

IN OUT

IN OUT

IN OUT

IN OUT

IN OUT

IN OUT

IN OUT

IN OUT IN OUT

Operation : Work Cell & Ownership concept Rev.2.0

Proposed Design @ 4200

R/M Supermarket

F/G Supermarket

Min-Max K/B

Air Cure 1 Hr

Drill Disassy Clean

Water Spider Internal Logistic

In- Line Process

Sep 11’2011 Rev 2.0

Sand Blast

End Plate Cutting

Sort Hopper

Hopper Seal

Drill Hopper

Refill Toner

Hopper+

Mag Roller + End Plate

Attach Clip Poka Yoke Picking Box

Remove Stricker

Silicone

Wiper Blade

PCR Cleaning

PCR+ Housing

Final Assy

Post Test Packing

Min-Max K/B

Remove Stricker

Production Control Board

Before After

No. of Operator 18 13

No. of Station 25 21

Distance ( meter )

( ไมรวมความถ )

448 0

Rework @ Post Test 30% 0%

Hight Light : 1. Poka Yoke Picking Box ( InprocessTray )

2. Closed loop @ Disassy + Clean

3. New design “ Sand Blast “

4. Send the current filling machine to additional modify

5. Small Wiper Blade 6. Process Excellence “ Change type of Silicone “

Lot Production - Monthly

C

Month

Req. One Month

A

B

300

100

200

Model

100

200

300

One Month

A

B

C

100

300

200

50

100

150

50

100

150

Model Month

Req.

Lot Production - Semi-Monthly

Types of Production

One Day

A

B

C

5

10

15

5 10

15

Month

Req. Model Day

Req.

300

100

200

Daily Production

FLOW

Day

Req. One Day

A

B

C

5

10

15

Model Month

Req.

300

100

200

Synchronized Production - Mixed Stream

Leveling Production (cont.)

112

Leveling

Leveling

Executive Line Mixed Flow Line

Multi Flow Line

ขนตอนท 3 : Poka Yoke Mapping


123

Poka Yoke Mapping :

Operation

Description #1 #2 #3 #4 #5 #6 #7 # 8 #9 #10 #11 Rwk C/S H/R

Monitor

Touch Screen Monitor

Bar Code Scanner

Bar Code Printer

LPS Software

Poka Yoke Lighting

PLC Program + Wiring

ToolNet

Prevent for wrong part

Prevent for no torque

Prevent for wrong bolt

As of Aug 13’2009

Off-Line

System Architecture

125

Poka Yoke Example : Pick to light

126

Poka Yoke Example : Light to Pick

ANDON SYSTEM

Because an image is worth a thousand words

What does it mean?

In 'ancient' Japanese, Andon was a paper lantern (a handy vertically collapsible paper lampshade with an open top and a candle placed at the central section of the closed bottom). It functioned as a flashlight, a signaling device in distance, or even a commercial sign.

ANDON

Definition: Plant floor process control and communication system used to signal abnormal or out of standard conditions.

ANDON

So, why does it get used? In order to provide the ability for operators to call for assistance and obtain support to

contain build problems in station. Nowadays, Andon at many manufacturing facilities is an electronic device: audio

and/or color-coded visual display. For example, suppose an Andon unit has three color zones (red, green, and orange) and when the orange zone flashes with a distinctive sound, it calls the attention

and is signaling an operator to replenish certain material.

A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

Andon

Andon display boards

ANDON examples

Position of the lights above the line for Easy Visual Management

Signification of the lights (Scan Workstation) :

• Flashing Green >>>>>> Scan OK

• Flashing Orange>>>>>> Above Time

Andon flashing lights

ANDON examples

In order to ensure a rapid response, each Team Leader

should have a small number of operators to manage

and that small team should be a group working

together to improve the quality in their cell! When one

workstation of the cell stops and the Andon alarms go

on, there’s no point in having the rest of the

workstations working – in fact, the other members of

the team should participate in finding the root cause of

the problem that caused the stoppage and put in place

mechanisms to avoid the same situation in the future

(eg: Poka Yokes).

ANDON

Be aware!

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

456200 997846 4981654

A107 A108

Audio signals (music/tones) provide audible

signals when Andon system is activated.

Andon Visual Display Board Positioning (Overhead View)

FPS FPS FPS FPS FPS FPS FPS FPS FPS

FPS FPS FPS FPS FPS FPS FPS FPS FPS

“A” Line

Aisle

Aisle

Andon Display Board

Suspended Middle of Line

Marks

on

Floor

Work

Station

Lights

Viewable in

two directions

Fixed

Position

Stop

LED Messages

Andon Call Line Stopped

Andon Call Line Running

Line Running Normal Operation

1 2 3 4 5 6

7 8 9 10 11 12

Emg.

Stop

Buffer

Full

Error

Proof Maint. Plan Actual

Front Seat Line

Unique tone or music

by team or area.

Error Proofing Device Fault

Emergency Stop

End of Line Buffer Full Maintenance Breakdown

Scheduled Production

Actual Production

A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

Workstation Stack Lights

Line Address Sign

A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

Line Running

Normal Operation

No Andon Calls

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

Andon Call

Line Running

at 12th Operation

Andon Call

Line Stopped

at 12th Operation

Andon Workstation Light & Unique Audio Tone

A112

A112

Line Running

Error Proofing Fault

at 1st Operation

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

1 2 3 4 5 6

7 8 9 10 11 12 Emg.

Stop

Buffer

Full

Error

Proof Maint.

Plan Actual

Front Seat Line

Line Stopped

End of Line

Buffer Full

Line Stopped

Error Proofing Fault

at 1st Operation

A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

A-107A-107

Andon

Stop

Andon

Call

Normal(No Call)

Over

Cycle

Andon Workstation Light & Unique Audio Tone

A101

A - 107

Andon Stop

Andon Call

Normal (No Call)

Over Cycle

A - 107

Andon Stop

Andon Call

Normal (No Call)

Over Cycle

A101

ขนตอนท 4 : PFEP


140

ขนตอนการประยกต PFES & PFEP

ขนตอนท 1 : Plan For Each Station ( PFES ) : ค านวณหาความตองการในแตละสถานงาน ( Lineside presentation requirement )

ขนตอนท 2 : Standard Packaging : ก าหนดมาตรฐานบรรจภณฑ ขนตอนท 3 : Plan For Every Part ( PFEP ) ค านวณปรมาณและความถในการสงของแตละชนงาน 1. Center supermarket

2. Signal

3. จ านวน Water Spider

141

Foundation

• On-Hand Inventory considerations

• Bulk Storage requirement

• Central Supermarket requirement

• Line Side presentation requirement

• Material Flow planning

• Material Handling planning

• Pull System / Kanban

• Plan For Each Station (PFES)

What is it?

142

• Requirements:

• Accurate Bill of Material (BOM)

• Accurate customer forecast

• Accurate “Weekly Component Schedule”

• Packaging dimensions

• Packaging Standard Pack quantities

What do I need to create it?

143

ขนตอนท 1 : Begin to populate the PFEP spreadsheet

Part # Part Description Supplier Std Pck Cntnr Retrn

or Exp Container Size

Width

(cm) Length (cm)

Height (cm)

A001 Bracket Supplier 1 20 Return 12 24 10

• Row, Part Name, Part # & Color, Supplier, Std Pack

• Container info – dimensions, returnable or expendable etc.

144

ขนตอนท 2 : Add usage data

Part # Part

Description Usage Part Delivery

Avg Wkly

Usage Avg Daily

Usage Cntrs per

day Station # Super

Market

(Y/N)

Sequence

(Y/N)

A001 Bracket 1,000 1,000/5 = 400 400/20 = 20 1 Y N

• Avg weekly use from actual customer schedule

• Station # and whether it’s a bulk or supermarket part

145

ขนตอนท 3 : Line Side Calculations

Station # Part # Part

Description Min. Station side inventory Max. Station side inventory

Min. Inv.

Hours on

hold Min Inv Min

Contnr

Max. Inv.

Hours on

hold Max Inv Max

Contnr

1 A001 Bracket 2 (400/8) x 2 =100

100/20 = 5

4 (400/8) x 4 =200

200/20 = 10

• Assumes Min of 2 hours / Max of 4 hours

• Calculates requirements and rounds up to Standard Pack

146

ขนตอนท 4 : Storage Calculations

Part # Part

Description

Part

Location at

supermarket

Inventory control - Supermarket

Max Inventory

Hours OH

~

Include Safety Stock

Max Inv.

Max Cntnr

Cntnr per

pallet

A001 Bracket A15 24 24 x 20 = 480 480 / 20 = 24 24 / 6 =4

• How many hours on hand (based on receiving schedule)

147

• Layout Bulk Storage to actual utilization

• Layout Supermarket correctly

• Institute Kanban

• Max Line Side Column = # of Kanbans

• Develop flow lanes / delivery routes

• Consolidate material handling roles

• Control material / packaging handling

• Apply Visual Management techniques

ขนตอนท 5 : Apply the tools

148

4527864 9973421

5673021 9856482

Small Lot Delivery to Workstation.

Returnable container with

lift handles or slots weighing

less than 20 kg. each.

Maximize Trailer Liquid Cube Utilization

ตวอยางการจายวตถดบ

149

Lift Out Returnable Containers

Small Lot Delivery to Workstations

4527864 9973421

5673021 9856482


150

Smart Manifest

Sequencing

Smart Manifest

Sequencing

Smart Manifest

Sequencing

In-Build Sequence Delivery from Supplier

Dolly Delivery to Workstation

In-Plant Build Order Sequencing


151

4527864 9973421

5673021 9856482

Downsize (Repack)

to Smaller Containers

Downsize (Repack)

Bulk Sequencing

25

20

30


152

Small Container Conveyance & Central Material Storage

Rack 1 Rack 2

B

A

B

A

B

A

Central Material Storage

Empty

Containers

X

Standardized routes delivering

small containers on a frequent

schedule (once per hour or less).

More frequent deliveries lower

material inventory at operations.

12 1 2

3

Overflow Only

B

A

Shelf Level

Designation

• Labels affixed to rack using Velcro

backed clear plastic pockets.

• Labels located directly below

containers on the front & back of rack.

• Label content includes: Part name,

Part number, Standard pack size,

Minimum and Maximum Quantity.

• Label size as defined

• Racks identified by section and

shelf levels.

Part: Side Shield

Part No: 9873214

Std. Pack: 60

Min. 2 Max. 5

CHI DET NY BOS PHI MIN

Returnable Container Sorting Area

Rack 3

153

Work shop : Apply PFEP & PFES

Working Plan

Develop Master Data Base for Plan for Every Part (PFEP)

Std Pack Qty

Packaging Sizes

Packaging Type (Expired vs Returnable)

Receiving Frequency plus Safety Stock (Hours on Hand)

Develop Plan for Each Station (PFES)

Lineside Presentation

2 to 4 Hours where possible (Kanban Cards)

Plan for Bulk Replacement Signals

Develop Routing for Every Part - Bulk / Sequence / Mkt Place

Origin to Point of Use Routes

Material Handling Equipment Requirements

154

Workshop PFEP & PFES

Working Plan ( Cont. )

Develop Material Storage Plan

Market Place Location

Bulk Storage Locations

Address System

Flow Racks, Straight Racks

Develop Inbound / Outbound Procedures

Receiving Schedule

Returnable Container Procedures (Freq / Ratio to Delivery)

Determine ManPower Requirements to Support Production

Lift Truck (Tow Motor) Personnel

Tugger

Marketplace Support

155

Standard Packaging

156

Standard Packaging

157


Rack 1 Rack 2

B

A

B

A

B

A

B

A

Rack 3

Len

B

A

Rack 4

B

A

Rack 5

Frame Reflector Pole Battery

Rack 6

B

A

B

A

Body

ขนตอนท 5 : Supermarket :

Shopping Area


A-107 Line “A” Designation

Product Designator:

- Front Row “100 Series

- Second Row “200 Series

- Third Row “300” Series

Sequential Line Space

Locator “07”

8.5 (inches)

3.5

” (

inch

es)

Page 6 of 13 Revision Date: 06/11/03

A-107

Andon

Stop

Andon

Call

Normal (No Call)

Over

Cycle

Linear Conveyor Sequential Address System Configuration

A

B

C

D

A-1

01

A-1

02

A-1

03

A-1

04

A-1

08

A-1

05

A-1

06

A-1

07

A-1

08

A-1

06

A-1

07

B-1

01

B-1

02

B-1

03

B-1

04

B-1

08

B-1

05

B-1

06

B-1

07

B-1

08

B-1

06

B-1

07

C-1

01

C-1

02

C-1

03

C-1

04

C-1

08

C-1

05

C-1

06

C-1

07

C-1

08

C-1

06

C-1

07

D-1

01

D-1

02

D-1

03

D-1

04

D-1

08

D-1

05

D-1

06

D-1

07

D-1

08

D-1

06

D-1

07

A-108A-108A-108

8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft.

One Pitch (Footprint = 8 ft. spacing)

Sequential Line

Address Affixed

to Stack Lights

Front

Seat

Line

Second

Seat

Line

Third

Seat

Line

Other

Seat

Line

Linear Conveyor Sequential Address System Configuration

A132 8.5 (inches)

3.5

” (

inch

es)

A132

Andon

Stop

Andon

Call

Normal (No Call)

Over

Cycle

Grid Layout Address System Configuration

A

B

1

2

3

1 2 3 1 2

A132

10

20

30

40

Feet

Column A1

Sub-section 3

Sub-section 2

A-111

A-1

23

A-131

C-213

C-211

C-233

C-212

C-231

Grid Layout Address System Configuration

1 2 3 4 5

1 2 3 1 2 3 1 2 3 1 2 3 A

B

D

E

C

1

2

3

1

2

3

1

2

3

1

2

3

10

20

30

40

Feet

Part: Adjuster

Part No: 9981427

Std. Pack: 90

Min: 1 Max: 3

Stack: 3 High

• Sign suspended directly above containers using wire, chain or conduit.

• Clear plastic sleeves used to protect sign.

• Type font size must be clearly visible.

• Sign content includes: Part name, Part number, Standard pack size, Minimum

quantity, Maximum quantity and Maximum stack height.

• Signs are 24 x 18 inches and font size must be adequate to make signs

clearly visible.

Central Material Storage Bulk Container Visual Aids

18’

Part:

Part No:

Std Pack:

Min. Max.

Stack:

18”

24”

Draft

Small (Hand Delivery) Parts Central Material Storage

Part: Side Shield

Part No: 9873214

Std. Pack: 60

Min. 2 Max. 5

• Labels affixed to rack using Velcro backed

clear plastic pockets.

• Labels located directly below containers on the

front & back of rack.

• Label content includes: Part name, Part number,

Standard pack size, Minimum Quantity and

Maximum Quantity.

• Labels are 6 x 4 inches for standard flow

racks and 3 ½ x 2 ½ inches for pipe style flow racks.

• Racks identified by section and shelves.

Rack 1 Rack 2 Rack 3

C

B

A

C

B

A

Part: Side Shield

Part No: 9873214

Std. Pack: 60

Min. 2 Max. 5

6”

4”

Rack Label

Velcro Backed

Clear Plastic Laminate

Pocket

Draft

3 ½”

2 ½”

Small Container Presentation Visual Aids

Line Rack Labels

• Labels affixed to rack using Velcro backed clear plastic

pockets.

• Labels located directly below containers on the

front & back of rack.

• Label content includes: Part name, Part number, Standard

pack size, Minimum Quantity and Maximum Quantity.

• Labels are 4 x 6 inches for standard flow racks and

21/2 x 31/2 inches for pipe style flow racks.

Part: Bolt

Part No: 9958763

Std. Pack: 60

Min. 1 Max. 3

6

4”

Rack Label

Line Address Signs

• Attached to Stack Lights

• Alpha numeric numbering convention four (4) characters

- Spot 1: alpha line designator (e.g. “A” Line)

- Spot 2: numeric product designator (e.g. “1” = Front Row)

- Spot 3 & 4: numeric designator (e.g. “08” = 8th Space)

Line Flow Rack

(conventional style) Line Flow Rack

(pipe style)

Part: Side Shield

Part No: 9873214

Std. Pack: 60

Min. 2 Max. 5

Draft

A-108A-108A-108

Velcro Backed

Clear Plastic Laminate

Pocket

181


Rack 1 Rack 2

B

A

B

A

B

A

B

A

Rack 3

Len

B

A

Rack 4

B

A

Rack 5

Frame Reflector Pole Battery

Rack 6

B

A

B

A

Body

ตวอยาง Supermarket

Supermarket Design

Storage Address above pick point

Adjustable gravity racks

Supermarket Design

Safe. Well Guarded

Supermarket Design

Supermarket Design

189

Types of Expendable Packaging

• Interior Dunnage Types

– Layer pads

– Bags – LLDPE / HDPE

– Foam

– Partitions

• Bags

– Material Types

• Low Density Polyethylene

• Linear Low Density Polyethylene

• High Density Polyethylene

• Low and High Polyethylene

• Blend

• Silk Film

– Additives

• UVI

• Antistatic

• Slip

• Antiblock

– Colors

• Tints to Opaque

190

Types of Returnable Packaging

Baskets

Dunnage

Pallets

Pallet Boxes

Racks

Totes

Trays

Sleeve Packs

Foam

Plastic

Steel

Wood

Returnable Product Types

Material Types

Options

Hot stamps, labels, & silk screen printing

Label placards/ Card Holders

Lids: Attached or detached

Colors

Collapsible

Stackable

Drain Holes

191

32”L x 15”W x 7.5”H

24”L x 15”W x 7.5”H

*24”L x 15”W x 9.5”H

24”L x 15”W x 11.5”H

24”L x 15”W x 14.5”H

48”L x 15”W x 7.5”H

*12”L x 15”W x 7.5”H

12”L x 15”W x 9.5”H

24”L x 22.5”W x 7.5”H

*24”L x 22.5”W x 11”H

24”L x 22.5”W x 14.5”H

Selection Menu Standard Returnable Small Fixed-Wall Containers

Diversity recommended sizes for standardization

* Most common containers

Collapsible Pallet Box

Standard Pallet Box Sizes

32”L x 30”W x 25”H

32”L x 30”W x 34”H

48”L x 45”W x 25”H

*48”L x 45”W x 34”H

Extended Length Pallet Box Sizes

64”L x 48”W x 25”H

64”L x 48”W x 34”H

70”L x 48”W x 25”H

70”L x 48”W x 34”H

Selection Menu Standard Large Returnable Containers

Diversity recommended sizes for standardization

* Most common container

193

Benefits of Returnable Packaging

• Cost Savings

– Material

– Labor

– Disposal ( จ าหนาย )

– Elimination of Dunnage กนกระแทก • Environmental Issues

– Minimize the amount of waste sent

to landfills • Facility Maintenance Issues

– Cleaner and more functional plant

– Improve safety and ergonomics

– Increase floor space

– Easier Handling

– Common Sizes/Standardization

194

How Packaging Impacts Supply Chain

• Material Flow

– Inbound from Suppliers

– WIP (Work In Process)

– Outbound to Customer

• Inventory

– Levels and turns

– Lean Manufacturing practices

– Pull system

• Logistics

– Trailer density

– Frequency of delivery (JIT)

• Line Presentation requirements

– Space constraints – Height, floor layout,etc.

• Ergonomics

– Weight

– Handling

– OSHA Requirements

• Packaging Guidelines

– OEMs and Tier Suppliers can have their own packaging guidelines for incoming product.

ขนตอนท 5 : Routing :

Water Spider


1. จายตามเวลา : Fixed Peroid Supply การขนสงแบบก าหนดเวลาไมก าหนดปรมาณ เชน รถไฟ

3. จายตามล าดบ : Sequencial Supply

การปอนแบบเตมตามจ านวนใช ปอนชนสวนตามจ านวนทถกใชไป

การปอนตามล าดบ ปอนชนสวนตามล าดบการผลตในจ านวนทแนนอน

2. เบกจายตามจ านวน : Fixed Quantity Supply การขนสงแบบก าหนดปรมาณไมก าหนดเวลา เชนรถตไมเตมไมออก

ประเภทของการขนสง

Tugger & Dolly

180 Degree turn inside 10 Feet !!

Tugger & Dolly

Each Line / Area has own dolly

199

4527864 9973421

5673021 9856482

Small Lot Delivery to Workstation.

Returnable container with

lift handles or slots weighing

less than 20 kg. each.

Maximize Trailer Liquid Cube Utilization


200

Lift Out Returnable Containers

Small Lot Delivery to Workstations

4527864 9973421

5673021 9856482


201

Smart Manifest

Sequencing

Smart Manifest

Sequencing

Smart Manifest

Sequencing

In-Build Sequence Delivery from Supplier

Dolly Delivery to Workstation

In-Plant Build Order Sequencing


202

4527864 9973421

5673021 9856482

Downsize (Repack)

to Smaller Containers

Downsize (Repack)

Bulk Sequencing

25

20

30


203

Small Container Conveyance & Central Material Storage

Rack 1 Rack 2

B

A

B

A

B

A


Empty

Containers

X

Standardized routes delivering

small containers on a frequent

schedule (once per hour or less).

More frequent deliveries lower

material inventory at operations.

12 1 2

3

Overflow Only

B

A

Shelf Level

Designation

• Labels affixed to rack using Velcro

backed clear plastic pockets.

• Labels located directly below

containers on the front & back of rack.

• Label content includes: Part name,

Part number, Standard pack size,

Minimum and Maximum Quantity.

• Label size as defined

• Racks identified by section and

shelf levels.

Part: Side Shield

Part No: 9873214

Std. Pack: 60

Min. 2 Max. 5

CHI DET NY BOS PHI MIN

Returnable Container Sorting Area

Rack 3

poka yoke mapping - panyapiwat

Documents