8.3.1. Work Rebalance by ML SOS

8/13/2019 8.3.1. Work Rebalance by ML SOS

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Bill Of Process Delphi Restricted 8.3.1 / 1

Work Rebalanceby

Moving Line SOS


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Interaction between Static & Moving Objects

The Moving Line SOS is the tool used to document the standardised

work of operators who work on a conveyor based moving line, for

example the areas General Assembly and Tapping.

Advantages of the Moving Line SOS:

A summary of the current best method A visual control tool to ensure the operation is being performed

according to existing standards

A basis for problem solving and line rebalance Makes visible the waste in a process

A training tool to instruct new operators

Confirms the Weighted Average Cycle Time for the process

Moving Line


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Calculate the Takt Time

Confirm the Actual Takt Time

Calculate the Operation Rate

Confirm the start position for each process

Confirm the stop position (FPS) for the conveyor

Confirm volume status (volume gate) Confirm the quality status (quality gate)

Step 1 - System Fundamentals


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1st - Element Break

2nd - Create Element Sheets

Identify the Elements Create Element Sheets

Time the Elements

Step 2 - Grasping the current condition


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Create a Moving Line SOS

Identify the Walking

Confirm option impact

Calculate Weighted Average Cycle Time & Element Time Complete Work Position section

Complete Team Member Movement section

Complete Work Distribution section

Create a Moving Line SOS


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Create the Moving Line SOS


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The MLSOS has eight columns for showing the different models or

options that may impact one particular process. This may be different

for each workstation, and should be based upon the current schedule.

Simple Example - 8 or less possible variations

Model / Option Mix: KIT 14 F = 60% KIT 14 C = 36% KIT 14 Other= 4%KIT 17 E = 60% KIT 17 B = 36% KIT 17 Other= 4%

KIT 28 D = 78% KIT 28 B = 18% KIT 28 Other= 4%

Calculate the possible options using a tree:-

Confirm the Option Tree


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Simple Tree

1 5

2 6

3 7

4 8

Handwork / Model

15 15 15 15

2 2 2 2

185 185 185 185

14 8 8 4

42 42 42 42

Model 11

Other

Model 4

Model 8

4

3 Option for kit 14

1

Work

Element

Registered

Number

1

Ass embly of Kit 14

11

2

Read Manifest / Pickup Kit 14 and Components

8 other

2 3 4S

i

m

b

o

l

S

t

e

p

1

Assembly L322 LHD

2

Element Name

Operation WS3 - 5

Group / Team

3 Ass embly of Kit 17

5

4

Model Description

60%

60%

60%

36%

36%

18%

4%

4%

4%18%

438 430 432 424 0

11 11 11 11 0

eg

Cycle Time sec . 441 '' 443 ''

0 ''

0 ''

77 ''

18%

80 '' 17 ''

78 '' 17 ''

Volume % 60%

269 ''

Weightet Average Element Time

Weightet Average Cycle Time

263 ''

79 ''

18% 0%4%

435 '' 0 ''449 ''

ctuaa t me 460

Total Element Time / Walking by Model sec .

Mark which model is shown in each column

and fill in the volume %

Focus on the most representative models

(higher volume)


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Document the element time, cycle time and actual

takt time for every option shown on the SOS

Show Cycle Times


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High workload due to Model or Option mix can cause unevenness.

This unevenness makes it more difficult to utilise our manpower fully.

Team memberA Team memberB Team memberC

Balanced!

Basic Car With maximumNo. of Options With Sunroof+ Side Air BagsWith Sunroof

Wait Time!

Over cycle

Unevenness (Mura)


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1 5

2 6

3 7

4 8

Handwork / Model

15 15 15 15

2 2 2 2

185 185 185 185

14 8 8 4

42 42 42 42

Model 11

Other

Model 4

Model 8

4

3 Option for kit 14

1

Work

Element

Registered

Number

1

Assem bly of Kit 14

11

2

Read Manifest / Pickup Kit 14 and Com ponents

8 other

2 3 4S

i

m

b

o

l

S

t

e

p

1

Assembly L322 LHD

2

Element Name

Operation WS3 - 5

Group / Team

3 Assem bly of Kit 17

5

4

Model Description

Final Assembly Options Matrix

Moving Line

A

A

A

A

A B

BA

B

D

E

D

B C C D D

B C CD D

The operator sees in the manifest the option (model) to build.

By checking the Final Assembly Options Matrix he /she finds

the options of the kits to assemble.The operator can check the build sequence consulting the

ML SOS (see step column in the ML SOS)

The Team Leader can see if the operator is following the

right build sequence and times by comparing the activity ofthe operator with the ML SOS

Manifest


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Create Analysis Tools

Create a Work Distribution Chart

Create a Work Position Summary Sheet

Create a Location Map

Create a Work Area Map

Step 3 - Evaluation


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Show the Takt Time

Show the Actual Takt Time

Show the Weighted Average Cycle TimeShow the Weighted Average Element Time

TT

ATT

Element

Time

Cycle

Time

Process A

Create a Work Distribution Chart


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The Work Distribution Chart is not a NUMMI wall!

The function of the chart is to capture the "Big Picture" and not

to function as a tool for detailed line balancing.

Identify Waiting TimeIdentify Overburden

(Bottleneck)

Function of the Work Distribution Chart


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Confirm the Work Positions -

Confirm the # of Trips - Confirm the # of Locations

Create a Work Position Summary Sheet


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Create a Location Map

4.2

C W k A M


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Conflicts in team member movement

Working Area Map:

Current Condition

Direction of conveyor

Create a Work Area Map

Conflicts

367 5 4 2 111 89

13 15 17

1012

14 16 18 19 20 21 22 23 24

St 4 I f Fi l Sh


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- Achieve volume- No repair- No scrap- Full utilisation- Short lead time

......

What are theproblems?

What are the

current conditions?

Step 4 - Image of Final Shape

St 5 R d C l Ti


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One Point CIP ActivitiesFocus:

o Simple

o Low Cost

o Easy to implement

o Change the environment

Step 5 - Reduce Cycle Times

Theme

Before

After

Problem

Effect Cost

Material Location

Walking for Material

Reduction of walking 0

Stn 8L Stn 8R Stn 9L Stn 9R Stn 10L Stn 10R Stn 11Harness

Pick Total

Number of CIP

Ideas13 7 7 9 2 7 3 6 54

Cycle Time

Reduction0.43 0.32 0.31 0.58 0.12 0.64 0.20 0.10 2.70

Original Cycle

Time3.17 2.63 3.77 3.36 3.89 4.23 2.24 3.48 26.77

New Cycle Time 2.74 2.31 3.46 2.78 3.77 3.59 2.04 3.38 24.07

WS 1 WS 2 WS 3 WS 4 WS 5 WS 6 WS 7

St 6 A ti / R b l


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Look for:-

Dedicated equipment.Low average cycle time.

Single spread elements.

High locations.

Small elements.

This is done by transferring work

out from process to fill up theothers.

Establish a

target process

Consider the benefit achieved

from transferring workbetween processes

The objective is to gather

the available wait time

into one process.

Step 6 - Auction / Rebalance

Pickup

WiresCable

ChannelU.S

Splices 1/2Tapping

X 209Tapping

C. ChannelAssembly

KIT 10A

KIT

1APickup

KIT 1AAssembly

KIT 1A

Ground

Splice X1

Cover

Conn. A1

Step 6 Auction / Rebalance


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X

X1

4

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5Develop alternative combinations to reduce waste (Auction)Develop proposals for different combinations.

Trial and simulate.

Evaluate the new work position summary sheet.Make a new location map and compare to the old.

Create a draft New Moving Line SOS.

Confirm in a line trial.

Does it actually work ?. => Fix the final proposal

Finalise the new Moving Line SOS.

Re-establish the Work Element sheet folder.

Step 6 - Auction / Rebalance

Step 7 Result Confirmation


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process cycle times

No. processes x Act. TTx 100% = 100

AfterBefore

1260 = 60%

35 x 60

1260 = 66%

32 x 60

Takt Time

Act TT

Cycle time

Frequency Line Station

10

9 Example:

8

7

6

Old 5

4

3 6 10 14

2 5 9 8 11

1 2 12 7 3 1 13 4

0 1 2 3 4 5 6 7 8

1 3 2 8 1

2 4 13 9

3 5

4 6

New 5 9

6 10

7 11

8 12

9

10

Consider for evaluation of improvement:

Location map spread.Trip frequency.

No. of processes.

Percentage of member cycle time to Actual takt time.

Step 7 - Result Confirmation

7

3

Team Member Balance Chart


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Team Member Balance Chart

Documents

8.3.1. Work Rebalance by ML SOS