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Creating Connected Process Flow
MHR 5350
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Just-in-Time
Right part
Right amount
Right time
Right place
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One-piece Flow
Products are processed and moved directly to the next process one piece at a time
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“Flow where you can.
Pull where you can’t.
Don’t Push!”
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Flow Continuum
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Process A Process B Process C End User
Elapsed time:33 seconds
Push – Batch & Queue
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Process A Process B Process C End User
Elapsed time:15 seconds!
Pull – Continuous Flow
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Tools to Establish One-Piece Flow
Pull techniques Supermarkets/Kanban Sequenced Pull
Workplace/Cell design
Clearly defined customer/supplier relationships
Visual controls
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Pull
Defined agreement with specified limits pertaining to Volume of production Model mix Sequence of model mix
Dedicated
Controlled
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Pull Example: Simple Process
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Pull Example: Three Distinct Models
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Pull Example: High Product Variety
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Handoffs: Jobs moving through depts.
(inbox)
Waiting (Approvals, etc.)
Transaction Waste
Re-Invention Waste
Lack of ‘System Discipline’
High Process and Arrival Variation
System Over/Under-Utilization and
Expediting
Ineffective or Barriers to Communication
Redundant Tasks
In the Office…Flow issues?
“Stop and Go” TasksUseless Information (e.g., e-mails,
etc.)Designing features the customer
doesn’t needNot utilizing resources to their full
potential
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Kanban
Signal/Sign/Card
Visual control system used to trigger activity in upstream process Replenishment for production and material
Usually printed card Part number/description Quantity Location Picture Etc.
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Kanban Uses
Instruction
Self control to prevent overproduction
Visual control
Reduction of managerial cost
Reduction of inventory
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Kanban Advantages
Processes connected
Eliminates excess inventory Floor space Wasted material during model changeover Boxes/bins/returnables
Potential problem: people
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Kanban Rules
Downstream process should withdraw the right parts from the upstream process at the right quantity and right time
Upstream process should produce the parts in the quantities withdrawn by the downstream process
Defective products should never be transported to the downstream process
Number of kanbans should be minimized
Kanban can be utilized to adapt to small variation in production volume
Actual quantity of parts in bin/box/pallet must be equal to the quantity on kanban
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Kanban Example
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Kanban Example
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Kanban Example
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Kanban Example
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Think
If some problem occurs in one-piece flow manufacturing then the whole production line stops. Why is that a good thing?
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Advantages of One-Piece Flow
RAPID CONTINUOUS IMPROVEMENT
Build in quality
Increased flexibility
Higher productivity
Decreased floor space
Improved safety
Improved morale
Reduced inventory
Project Assignment Create current state map (45-60 minutes)
Present current state map
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Questions?