Creating Mixed Model Value Streamsinstituteopex.org/site/writeable/custom_uploads/a1f5eb9b368507ebb14… · © 2017 Institute for Operational Excellence. All Right Reserved. Abe Dabdoub,

Creating Mixed Model Value Streams

Abe DabdoubSenior Faculty Member

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© 2017 Institute for Operational Excellence. All Right Reserved.

Abe Dabdoub, EEng, MBA

Senior Faculty Member, Institute for Operational Excellence

Clients• United Technologies Corporation• FMC Technologies• Senior Aerospace• Sikorsky• Aetna

Credentials• Over 25 years of progressive operational excellence experience in

health insurance, oil & gas, aerospace, automotive and electronicsindustries.

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Continuous Improvement

Companies have done continuous improvement activities for years…

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Pareto

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Impact

Effort

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Improving Operations

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The Lean Journey

SustainImprove

SustainImprove

SustainImprove

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Operational Excellence

Mature lean company

Time in Years

Leve

l of i

mpr

ovem

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1 5 10

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Time in Years

Leve

l of i

mpr

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1 5 10

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The ‘Jump’ to Operational Excellence

Time in Years

Leve

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mpr

ovem

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1 5 10

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“When each and every employee can see the flow of value to the customer, and fix that flow before it breaks down.” SM

Kevin J. Duggan

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The Eight Steps to Achieve Operational Excellence

1. Design a lean flow using lean guidelines.2. Implement a lean flow.3. Make the lean flow visual.4. Create standard work for the lean flow.5. Make abnormal flow visual.6. Create standard work for the abnormal flow.7. Teach employees to maintain and improve the flow to

the customer.8. Free management to work on offense.

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Eight Guidelines for End-to-EndValue Stream Design

XOXO

Eight VS Guidelines1.

2.

3.

4.

5.

6.

7.

8.

Form Assembly Test Ship

FIFOFIFO

2 days 1 day 1 day 1 day 5 days2 sec 20 min 10 min 15 min 45 min

DailyWeekly

CustomerSupplier

Production Control6 Week

ForecastWeekly Orders

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Ten Guidelines for the Mixed Model Pacemaker

Ten MM Guidelines1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Pacemaker

XOXO


FIFOFIFO


DailyWeekly

CustomerSupplier



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Six Guidelines for Shared Resources Flow

Six S/R Guidelines

1.

2.

3.

4.

5.

6.Shared Resource Shared Resource

Form Test

XOXO

Assembly Ship

FIFOFIFO


DailyWeekly

CustomerSupplier



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Nine Guidelines for Office Flow

Nine Office Guidelines

1.

2.

3.

4.

5.

6.

7.

8.

9.

Customers Customers

Sales Database

email

Design Pkg.Create

File

Log File

P/T=15 min.1 CSR

Request Form

FIFO

4 Hrs.

4 Estimates per Day

L/TP/T

1.5 Days + 187 min

187 min.17 Min. 170 Min.

Max = 1.5 days

P/T=170 min.PC/T=55 min.

Op = 3

Takt = 60 min.

Post Office

0 – 1.5 days

email

Estimating Cell

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Seven Guidelines for Supply Chain Flow

Seven SC Guidelines

1.

2.

3.

4.

5.

6.

7.

Premier Rail Cars

Axle Co. Unlimited (WV)

Practical Solutions (MO)

FIFO

Beijing Walls China

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The Mixed Model Pacemaker

Ten MM Guidelines1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Daily

Pacemaker

CustomerSupplier



XOXO


FIFOFIFO

2 days 1 day 1 day 1 day 5 days

2 sec 20 min 10 min 15 min 45 min

Weekly

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Mix of Products Flow through the Same Value Stream

How will we run all these products through the same value stream when demand

changes each day?

Stamp

Pistons: 45-80 unitsBrackets: 50-90 unitsArms: 25-75 units

Collars: 30-55 unitsDiverters: 35-60 unitsDetectors: 20-40 units

Lifters: 55-75 unitsLevers: 60-95 unitsCranks: 40-70 units

Paint Assemble ShipFIFO

max 50

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Sequencing Box

123456789

A

A

A

B

B

B

C

D

E

VSM Illustration

Upstreammax. 50 piecesDownstream

ProcessProcess

Supermarket

X O X O

1 2 3 4

FIFO Lane

VSM Shared Res PS

Assembly

Supermarket

FIFO

* Changeover Time* Run Time / Container* Transport Time* Wait Time

How long before we get the first container back into the supermarket? Into Assembly?

Supply

Min Pull Signal

?

VSM Product Flow

max. 50 pieces

FIFO Lane

Ship

Assemble

Paint

Stamp

Collars...30-55 unitsDiverters...35-60 unitsDetectors...20-40 units

Pistons...45-80 unitsBrackets...50-90 unitsArms...25-75 units

Lifters...55-75 unitsLevers...60-95 unitsCranks...40-70 units

Buffer Cones

ORIGINAL BUFFER SETUP

Remove the cone when you use the box.

AFTER TWO WEEKS

You do not need any space where cones remain.

Sequencing Box

123456789

A

A

A

B

B

B

C

D

E

VSM Illustration


ProcessProcess

Supermarket

X O X O

1 2 3 4

FIFO Lane

VSM Shared Res PS

Assembly

Supermarket

FIFO



Supply

Min Pull Signal

?

VSM Product Flow

max. 50 pieces

FIFO Lane

Ship

Assemble

Paint

Stamp




Buffer Cones



AFTER TWO WEEKS



Which Type of Value Stream is this?

Degree of customization required

Numberof

Products

Discrete manufacturer

1

Discrete manufacturerHigh mix

2Job shop

Very high mixHigh customization

3

Low mixHigh customization

4

Make to Order Mfg.Discrete Mfg.

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Welcome to EMC Supply Co.

• In today’s class we will visit the Electro-Motion Control (EMC) Supply Co.

• EMC Supply Co. builds a wide variety of products for the motion control and electronics industries. They supply distributors and end users. They also build custom products to order.

• The management at EMC Supply Co. have stated that want to achieve self-healing value stream flow in their high mix environment.

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Mixed Model Value Streams

To produce a variety or mix of products or product variations through the same value stream…

AT THE PULL OF THE CUSTOMER.

Stamp

Pistons: 45-80 unitsBrackets: 50-90 unitsArms: 25-75 units

Collars: 30-55 unitsDiverters: 35-60 unitsDetectors: 20-40 units

Lifters: 55-75 unitsLevers: 60-95 unitsCranks: 40-70 units

Paint Assemble ShipFIFO

max 50

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Sequencing Box

123456789

A

A

A

B

B

B

C

D

E

VSM Illustration


ProcessProcess

Supermarket

X O X O

1 2 3 4

FIFO Lane

VSM Shared Res PS

Assembly

Supermarket

FIFO



Supply

Min Pull Signal

?

VSM Product Flow

max. 50 pieces

FIFO Lane

Ship

Assemble

Paint

Stamp




Buffer Cones



AFTER TWO WEEKS


Sequencing Box

123456789

A

A

A

B

B

B

C

D

E

VSM Illustration


ProcessProcess

Supermarket

X O X O

1 2 3 4

FIFO Lane

VSM Shared Res PS

Assembly

Supermarket

FIFO



Supply

Min Pull Signal

?

VSM Product Flow

max. 50 pieces

FIFO Lane

Ship

Assemble

Paint

Stamp




Buffer Cones



AFTER TWO WEEKS



Mixed Model Value Streams

EMC Product Family

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Key Questions and our Agenda

1. Do you have the right product families?

2. What is the takt time at the pacemaker?

3. Can the equipment support takt time?

4. What is the interval?

5. What are the balance charts for the products?

6. How will we balance flow for the mix?

7. How will we create standard work for the mix?

8. How will we create pitch at the pacemaker?

9. How do we schedule the mix at the pacemaker?

10.How do we deal with changes in customer demand?

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Product Family Matrix

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Product Family Matrix

P/N Name Inje

ctio

n M

oldi

ng

Stam

p

Debu

rr

Han

d De

burr

Pain

t

Wel

ding

Mec

hani

cal A

ssy

Elec

tric

al A

ssy

Fina

l Ass

y

Conf

igur

e &

Tes

t

Ship

12834 XS2 Servo Motor X X X X X X X18392 Sensor-Activated Arm X X X A X X X X X X X19283 Photoelectric Detector X X X X19299 Ionization Detector X X X X X21000 Laser-Activated Arm X X X X X X X X X X21032 Manual Servo Motor X X X X X X X21042 Manual Servo Motor II X X X X X X X22020 Manually-Activated Arm X X X A X X X X X X X23756 Fiber Optic Visual Sensor X X X X X X24783 XS3 Servo Motor X X X X X X X25030 Radon Detecter X X X X28121 Bar Code Divertor Piston X X X A X X X X X X X30000 Bar Code Diverter Arm X X X A X X X X X X X31000 Sensor-Activated Piston X X X A X X X X X X X31666 Laser Diverter X X X X X X X X X X32220 XS4 Servo Motor X X X X X X X34556 Carbon Monoxide Detector X X X X X35599 Auto Servo Motor X X X X X X X38200 Laser-Activated Piston X X X X X X X X X X42005 Manually-Activated Piston X X X A X X X X X X X45890 Motion Detector X X X X

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(1) X Map

P/NNameInjection MoldingStampDeburrHand DeburrPaintWeldingMechanical AssyElectrical AssyFinal AssyConfigure & TestShip

12834XS2 Servo MotorXXXXXXX

18392Sensor-Activated ArmXXXAXXXXXXX

19283Photoelectric DetectorXXXX

19299Ionization DetectorXXXXX

21000Laser-Activated ArmXXXXXXXXXX

21032Manual Servo MotorXXXXXXX

21042Manual Servo Motor IIXXXXXXX

22020Manually-Activated ArmXXXAXXXXXXX

23756Fiber Optic Visual SensorXXXXXX


25030Radon DetecterXXXX

28121Bar Code Divertor PistonXXXAXXXXXXX

30000Bar Code Diverter ArmXXXAXXXXXXX

31000Sensor-Activated PistonXXXAXXXXXXX

31666Laser DiverterXXXXXXXXXX


34556Carbon Monoxide DetectorXXXXX

35599Auto Servo MotorXXXXXXX

38200Laser-Activated PistonXXXXXXXXXX

42005Manually-Activated PistonXXXAXXXXXXX

45890Motion DetectorXXXX

(2) Sorted X Map

ACME Supply Company

SORTED X MAP

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipFAMILY

18392LED-Activated ArmXXXXXXAXXXXA

21000Laser-Activated ArmXXXXXXXXXXA

22020Manually-Activated ArmXXXXXXAXXXXA

28121Bar Code Divertor PistonXXXXXXAXXXXA

30000Bar Code Divertor ArmXXXXXXAXXXXA

31000LED-Activated PistonXXXXXXAXXXXA

31666Super Laser DivertorXXXXXXXXXXA

38200Laser-Activated PistonXXXXXXXXXXA

42005Manually-Activated PistonXXXXXXAXXXXA

12834XS2 Servo MotorXXXXXXB

21032Manual Servo MotorXXXXXXB

21042Manual Servo Motor IIXXXXXXB



35599Auto Servo MotorXXXXXXXB

19283Photoelectric DetectorXXXXC

19299Ionization DetectorXXXXXC

23756Fiber Optic Visual SensorXXXXXXC

25030Radon DetectorXXXXC

34556Carbon Monoxide DetectorXXXXXC

45890Motion DetectorXXXXC

(3) Content Matrix

ACME Supply Company

WORK CONTENT MATRIX

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTAL

18392LED-Activated Arm351459014010A3060130180X691

21000Laser-Activated Arm30130601603060100300X771

22020Manually-Activated Arm4514012017520A456090220X771

28121Bar Code Divertor Piston301359024015A306090300X861

30000Bar Code Divertor Arm5514510018030A6060105180X756

31000LED-Activated Piston601406512510A306090240X691

31666Super Laser Divertor6014024030030602404801451

38200Laser-Activated Piston601351201803060125480X1091

42005Manually-Activated Piston401358014510A3060100240X711

Work Content > 30%

(4) Remove Matrix

ACME Supply Company

WORK CONTENT MATRIX











Move to another product family

(5) Final Matrix

ACME Supply Company

FINAL PRODUCT FAMILY A MATRIX










Sequence in, limit mix

(6) Final Matrix Cell

ACME Supply Company

DEMAND MATRIX

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShipTOTALDEMAND









(7) ACME Process Map

Process MapSummaryLean ACME

ACME SUPPLY CO.

Times in seconds unless notedXXXXXXXXXX

Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburHand DeburPaintFinal AssemblyConfigure & Test

DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer

LED-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065065603600750065130845065180117006911265ABC

Laser-Activated Arm210008995%360030627885270012785853003028508560510085160136008530255085603600870085100850085300255007711385ABC

Manually-Activated Arm220203795%360045525435270012735353004017003512042003517561253520700350356036005700359031503522077007711335ABC

Bar Code Divertor Piston281217495%36003058057027001277070300352750709063007024016800701510507007060360078007090630070300210008611470SS

Bar Code Divertor Arm300005395%36005564885027001275050300452550501005000501809000503015005005060360066005010552505018090007561350SS

LED-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505505560360069005590495055240132006911255SS

Laser-Activated Piston382002195%36006048602027001272020300351000201202400201803600203060020603600480020125250020480960010911820SS

Manually-Activated Piston420052695%360040465025270012725253003511752580200025145362525102502502560360051002510025002524060007111225SS

Custom Orders (10%)XXX4795%3600556199452700127454530030165045954275451607200453013504504560360063004510547254522099007561345Custom

TOTAL TIME5258624750Wct=37.111111111119400Wct=8638700Wct=168.7222222222759256050315059400Wct=102.944444444446325Wct=252.44444444441136007099118450

TOTAL QUANTITY473450450450450345450450450450

W=5400047808547204860054000540005400054000486005400054000

PROCESS PACE TIME101.2121.6108.0120.0120.0156.5120.0108.0120.0120.0

RESOURCES1.100.450.400.721.410.110.061.220.862.10

REVISED:6/21/01BAM

&LRev B&CPrepared By: BAM -- Duggan && Associates Inc.&R&D

Brian A. Moffitt:1 shift = 450 minutes2 shifts = 900 minutes

Brian A. Moffitt:100T press83% uptime95% Yield

Brian A. Moffitt:Range 120-240 sec

Brian A. Moffitt:Range: 90-130 sec


Brian A. Moffitt:95% uptime 2 shifts 8 hours/shift

Brian A. Moffitt:150T press95% uptime

Brian A. Moffitt:83% Uptime2 shifts8 hours/shift

Brian A. Moffitt:Uptime = 90%Changeovers = 5 min

Brian A. Moffitt:%Uptime = 90%

Brian A. Moffitt:90% uptime

Brian A. Moffitt:30-45 range

Summary

(8) Summary

DeburPaintHand Debur

0.111.220.06

StampWeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test

0.450.400.721.410.862.10

Injection Mold

1.10GO TO PROCESS MAP

TOTAL RESOURCES:8.43

&LPerkin Elmer Instruments&CProcess Map Summary Sheet&RLean GC

&LPrepared By: BAM -- Duggan && Associates Inc.&R&D

GO TO PROCESS MAP


Three Potential Families

P/N Name Hand

Deb

ur

Pain

t

Wel

ding

Mech

anic

al A

ssy

Elec

trica

l Ass

y

Fina

l Ass

y

Conf

igur

e &

Test

Ship

FAMI

LY

18392 Sensor-Activated Arm A X X X X X X X A21000 Laser-Activated Arm X X X X X X X X A22020 Manually-Activated Arm A X X X X X X X A28121 Bar Code Divertor Piston A X X X X X X X A30000 Bar Code Divertor Arm A X X X X X X X A31000 Sensor-Activated Piston A X X X X X X X A31666 Laser Divertor X X X X X X X X A38200 Laser-Activated Piston X X X X X X X X A42005 Manually-Activated Piston A X X X X X X X A12834 XS2 Servo Motor X X X X B21032 Manual Servo Motor X X X X B21042 Manual Servo Motor II X X X X B24783 XS3 Servo Motor X X X X B32220 XS4 Servo Motor X X X X B35599 Auto Servo Motor X X X X B19283 Photoelectric Detector X X X X C19299 Ionization Detector X X X X X C23756 Fiber Optic Visual Sensor X X X X X X C25030 Radon Detector X X X X C34556 Carbon Monoxide Detector X X X X X C45890 Motion Detector X X X X C

A

B

C

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Refine by Work Content

Name Ha

nd

De

bu

r

Pa

int

We

ldin

g

Me

ch

an

ica

l Ass

y

Ele

ctr

ica

l Ass

y

Fin

al A

ssy

Co

nfi

gu

re &

Te

st

Sh

ip

TO

TA

L

A Sensor-Activated Arm 30 60 45 90 140 130 110 X 605

B Laser-Activated Arm 30 60 30 60 140 100 110 X 530

C Manually-Activated Arm 45 60 40 120 150 90 100 X 605

D Bar Code Diverter Piston 30 60 35 90 180 140 110 X 645

E Bar Code Diverter Arm 60 60 45 100 180 105 105 X 655

F Sensor-Activated Piston 30 60 40 85 105 90 90 X 500

G Laser-Activated Piston 30 60 35 150 130 140 200 X 745

H Manually-Activated Piston 30 60 35 80 145 100 100 X 550

I Laser Diverter 30 60 40 240 300 240 80 X 990

X Custom Orders 30 60 30 120 160 105 110 X 615

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(1) X Map

ACME Supply Company

X MAP

P/NNameInjection MoldingStampDeburHand DeburWeldingPaintMechanical AssyElectrical AssyFinal AssyConfigure & TestShip

12834XS2 Servo MotorXXXXXX

18392Sensor-Activated ArmXXXAXXXXXXX



21000Laser-Activated ArmXXXAXXXXXXX

21032Manual Servo MotorXXXXXX

21042Manual Servo Motor IIXXXXXX

22020Manually-Activated ArmXXXAXXXXXXX



25030Radon DetectorXXXX

28121Bar Code Divertor PistonXXXAXXXXXXX

30000Bar Code Divertor ArmXXXAXXXXXXX

31000Sensor-Activated PistonXXXAXXXXXXX

31666Laser DivertorXXXAXXXXXXX




38200Laser-Activated PistonXXXAXXXXXXX

42005Manually-Activated PistonXXXAXXXXXXX


(2) Sorted X Map

ACME Supply Company

SORTED X MAP

P/NNameInjection MoldingStampDeburWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipFAMILY

18392Sensor-Activated ArmXXXXXAXXXXXA

21000Laser-Activated ArmXXXXXAXXXXXA

22020Manually-Activated ArmXXXXXAXXXXXA

28121Bar Code Divertor PistonXXXXXAXXXXXA

30000Bar Code Divertor ArmXXXXXAXXXXXA

31000Sensor-Activated PistonXXXXXAXXXXXA

31666Laser DivertorXXXXXAXXXXXA

38200Laser-Activated PistonXXXXXAXXXXXA

42005Manually-Activated PistonXXXXXAXXXXXA













(3) Content Matrix

ACME Supply Company

NameHand DeburPaintWeldingMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL

ASensor-Activated Arm30604590140130110X605

BLaser-Activated Arm30603060140100110X530

CManually-Activated Arm45604012015090100X605

DBar Code Diverter Piston30603590180140110X645

EBar Code Diverter Arm606045100180105105X655

FSensor-Activated Piston306040851059090X500

GLaser-Activated Piston306035150130140200X745

HManually-Activated Piston30603580145100100X550

ILaser Diverter30604024030024080X990

XCustom Orders306030120160105110X615

(4) Remove Matrix

ACME Supply Company

WORK CONTENT MATRIX

P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL

18392Sensor-Activated Arm4560309014013025X520


22020Manually-Activated Arm4060451201759060X590

28121Bar Code Divertor Piston356030902409030X575

30000Bar Code Divertor Arm45606010018010530X580

31000Sensor-Activated Piston406030651259045X455

31666Laser Divertor40603024030024030X940


42005Manually-Activated Piston3560308014510045X495


(5) Final Matrix

ACME Supply Company

FINAL MATRIX

P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTAL









(6) Final Matrix Cell

ACME Supply Company

FINAL MATRIX

P/NNameWeldingPaintHand DeburMechanical AssyElectrical AssyFinal AssyConfigure & TestShipTOTALCell TimesCell Cycle TimeDemand









485

total work


ACME SUPPLY CO.

Times in seconds unless notedXXXXX

WeldMechanical AssemblyElectrical AssemblyFinal AssemblyConfigure & Test

DescriptionP/NQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer

Sensor-Activated Arm18392653004532256590585065140910065130845065180117005851065ABC

Laser-Activated Arm210008530030285085605100851601360085100850085240204005901085ABC

Manually-Activated Arm2202035300401700351204200351756125359031503522077006451135ABC

Bar Code Divertor Piston28121703003527507090630070240168007090630070200140006551170SS

Bar Code Divertor Arm30000503004525505010050005018090005010552505018090006101050SS

Sensor-Activated Piston310005530040250055653575551256875559049505524013200560955SS

Laser-Activated Piston38200203003510002012024002018036002012525002048096009401620SS

Manually-Activated Piston4200525300351175258020002514536252510025002524060006001025SS

Custom Orders (10%)XXX45300301650459542754516072004510547254522099006101045Custom

TOTAL TIMEWct=37.111111111119400Wct=8638700Wct=168.722222222275925Wct=102.944444444446325Wct=225.555555555610150062010450

TOTAL QUANTITY450450450450450

W=540004860054000540005400054000

PROCESS PACE TIME108.0120.0120.0120.0120.0

RESOURCES0.400.721.410.861.88

REVISED:6/21/01








Summary



ACME SUPPLY CO.

Times in seconds unless notedXXXXXXXXX

Injection MoldStampWeldMechanical AssemblyElectrical AssemblyDeburPaintFinal AssemblyConfigure & Test

DescriptionP/NQuantityYieldSetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantitySetup TimeCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantity @ 100% YieldCycle Time (sec)TIME (sec)QuantityCycle TimeTOTAL TIMEQuantityCycle TimeDwell TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMEQuantityCycle TimeTOTAL TIMETotal Cycle Time (sec)Total Cycle Time (min)Pmax (Daily)Customer

Sensor-Activated Arm183926895%3600355989652700127656530045322565905850651409100651065065603600750065130845065180117006911265ABC





Sensor-Activated Piston310005895%360060706555270012755553004025005565357555125687555105505560360069005590495055240132006911255SS





TOTAL QUANTITY473450450450450450450450450

W=54000478085472048600540005400054000486005400054000

PROCESS PACE TIME101.2121.6108.0120.0120.0120.0108.0120.0120.0

RESOURCES1.100.450.400.721.410.161.220.861.88

REVISED:6/21/01BAM














Summary

(8) Summary

DeburPaint

0.161.22


0.450.400.721.410.861.88

Injection Mold





GO TO PROCESS MAP


Current State Map

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10. How do we deal with changes in customer demand?

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Takt Time for the Mix

• Takt time = customer demand rate for the entire family.

• Need to select time period and understand limits of the mix

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Takt Time Example

Name DEM

AND

Sensor-Activated Arm 65

Laser-Activated Arm 85

Manually-Activated Arm 35

Bar Code Diverter Piston 70

Bar Code Diverter Arm 50

Sensor-Activated Piston 55

Laser-Activated Piston 20

Manually-Activated Piston 25

Custom Orders 45

Total Demand 450

Effective Time = 900 min. *

* 2 shifts x (8 hrs. - .5 hrs.)

TAKT = 2 min. Effective Time

Total Demand =

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(1) X Map

ACME Supply Company

PRODUCT FAMILY MATRIX

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShip


18392LED-Activated ArmXXXXXXAXXXX






22020Manually-Activated ArmXXXXXXAXXXX




28121Bar Code Divertor PistonXXXXXXAXXXX

30000Bar Code Divertor ArmXXXXXXAXXXX

31000LED-Activated PistonXXXXXXAXXXX

31666Super Laser DivertorXXXXXXXXXX





42005Manually-Activated PistonXXXXXXAXXXX


(2) Sorted X Map

ACME Supply Company

SORTED X MAP























(3) Content Matrix

ACME Supply Company

WORK CONTENT MATRIX





28121Bar Code Diverter Piston301359024015A306090300X861

30000Bar Code Diverter Arm5514510018030A6060105180X756


31666Super Laser Diverter6014024030030602404801451



Work content is not within 80%.

(4) Remove Matrix

ACME Supply Company

WORK CONTENT MATRIX












(5) Final Matrix

ACME Supply Company

WORK CONTENT & DEMAND MATRIX










VariousCustom Orders551309516030A3060105220X75645

(6) Resource Matrix

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyElectrical Assy Run TimeDeburrHand DeburrPaintFinal AssyConfigure & TestConfigure & Test Total TimeDEMAND

18392Sensor-Activated Arm3514590140910010A30601301801170065

21000Laser-Activated Arm301306016013600306010030085

22020Manually-Activated Arm45140120175612520A45609022035

28121Bar Code Diverter Piston30135902401680015A30609020070

30000Bar Code Diverter Arm55145100180900030A606010518050

31000Sensor-Activated Piston6014065125687510A30609024055

38200Laser-Activated Piston601351201803600306012548020

42005Manually-Activated Piston4013580145362510A306010024025

VariousCustom Orders5513095160720030A306010522045

Total Demand75925450

Available time = 54000 sec5400054000

MACHINES REQUIRED1.4



ACME SUPPLY CO.














TOTAL QUANTITY473450450450450345450450450450

W=5400047808547204860054000540005400054000486005400054000


RESOURCES1.100.450.400.721.410.110.061.220.862.10

REVISED:6/21/01BAM














Summary

(8) Summary


0.111.220.06


0.450.400.721.410.862.10

Injection Mold





GO TO PROCESS MAP













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Determining Equipment Needs

Name Conf

igur

e &

Tes

t C/T

DEM

AND

Conf

igur

e &

Tes

t To

tal T

ime

A Sensor-Activated Arm 110 65 7150

B Laser-Activated Arm

C Manually-Activated Arm

D Bar Code Diverter Piston

E Bar Code Diverter Arm

F Sensor-Activated Piston

G Laser-Activated Piston

H Manually-Activated Piston

X Custom Orders

TIME NEEDED

Effective Working Time

Machines RequiredSum

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(1) X Map

ACME Supply Company

PRODUCT FAMILY MATRIX

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyDeburHand DeburPaintFinal AssyConfigure & TestShip


18392LED-Activated ArmXXXXXXAXXXX






22020Manually-Activated ArmXXXXXXAXXXX




28121Bar Code Divertor PistonXXXXXXAXXXX

30000Bar Code Divertor ArmXXXXXXAXXXX

31000LED-Activated PistonXXXXXXAXXXX

31666Super Laser DivertorXXXXXXXXXX





42005Manually-Activated PistonXXXXXXAXXXX


(2) Sorted X Map

ACME Supply Company

SORTED X MAP























(3) Content Matrix

ACME Supply Company

WORK CONTENT MATRIX





28121Bar Code Diverter Piston301359024015A306090300X861

30000Bar Code Diverter Arm5514510018030A6060105180X756


31666Super Laser Diverter6014024030030602404801451



Work content is not within 80%.

(4) Remove Matrix

ACME Supply Company

WORK CONTENT MATRIX












(5) Final Matrix

ACME Supply Company

WORK CONTENT & DEMAND MATRIX










VariousCustom Orders551309516030A3060105220X75645

(6) Resource Matrix

P/NNameInjection MoldingStampWeldingMechanical AssyElectrical AssyElectrical Assy Run TimeDeburrHand DeburrPaintFinal AssyConfigure & Test C/TDEMANDConfigure & Test Total Time

18392ASensor-Activated Arm3514590140910010A3060130110657150

21000BLaser-Activated Arm301306016003060100

22020CManually-Activated Arm45140120175020A456090

28121DBar Code Diverter Piston3013590240015A306090

30000EBar Code Diverter Arm55145100180030A6060105

31000FSensor-Activated Piston6014065125010A306090

38200GLaser-Activated Piston6013512018003060125

42005HManually-Activated Piston4013580145010A3060100

VariousXCustom Orders5513095160030A3060105

9100TIME NEEDED

Effective Working Time

Machines Required



ACME SUPPLY CO.














TOTAL QUANTITY473450450450450345450450450450

W=5400047808547204860054000540005400054000486005400054000


RESOURCES1.100.450.400.721.410.110.061.220.862.10

REVISED:6/21/01BAM














Summary

(8) Summary


0.111.220.06


0.450.400.721.410.862.10

Injection Mold





GO TO PROCESS MAP













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Interval for the Mix

• In a mix environment we must define the Interval in which the pacemaker will run the mix of products.

• The concept of the interval must be clearly understood.• You may have hear the term ‘EPEI’ which stands for

Every Product Every Interval.

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The Interval

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The Interval

1 Week

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The Interval

1 Day

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Is there Enough Time for Changeovers?

We would compare the total time needed to the effective working time per interval. Any left over time can be used for changeovers.

Effective working time per interval

Total time needed per interval

Time left for changeovers

Machine station

Time900 min.

800 min.100 min.

10 Products in the Family

Max C/O time = 10 min.

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How will we Flow Work through the Pacemaker?

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Balance Charts

Current State

Common Tools

Future State

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Current State Future State

Operator Balance Chart - Part B(Laser-Activated Arm)

140 sec.Takt = 120 sec.

110 sec.100 sec.

Elect.Assembly

Final60 sec. Assembly Config

& TestMech.

30 sec. Assembly

Welding

Operator Balance Chart - Part B(Laser-Activated Arm)

Takt = 120 sec.

110 sec. 110 sec. 110 sec.

FinalElect. Assembly

Assembly

65 sec.Mech. Config.

Assembly Elect. & TestAssembly

FinalAssembly

Welding

Eliminate Walking

Common Tools

Operator Balance Chart - Part A (Sensor-Activated Arm)

140 sec.Takt = 120 sec. 130 sec.

110 sec.

90 sec. Elect.Assembly Final

AssemblyConfig

Mech. & Test45 sec. Assembly

Welding

Operator Balance Chart - Part A (Sensor-Activated Arm)

Takt = 120 sec.

110 sec. 110 sec. 110 sec.

100 sec.

Mech. Elect. FinalAssembly Assembly Assembly

Config.& Test

Welding

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Work Content Times by Process

WORK CONTENT BY PROCESS

(CURRENT STATE)

PARTWELDPAINTHAND DEBURRMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TEST

A45603090140130110605405

B30603060140100110530330

C40604512015090100605400

D35603090180140110645445

E456060100180105105655430

F406030851259090520340

G356030150130140200745455

H35603080145100100550360

CUSTOM456030120160105110630430


(FUTURE STATE)

PARTWELDMECH. ASSYELECT. ASSYFINAL ASSYCONFIG & TESTWORK CONTENTASM. LESS TESTWC % Reduction

A357511010011043032026.56%

B25501209011039528515.79%

C301001108510042532523.08%

D30901601251105154059.88%

E40751407510543533030.30%

F358012085904103206.25%

G301351301402006354354.60%

H30701259510042032012.50%

CUSTOM35901109011043532532.31%

B-Charts-Current All Products

Operator Balance Chart - Part AOperator Balance Chart - Part B

(Sensor-Activated Arm)(Laser-Activated Arm)

140 sec.140 sec.

Takt = 120 sec.130 sec.Takt = 120 sec.

110 sec.110 sec.

100 sec.

90 sec.Elect.Elect.

AssemblyFinalAssembly

AssemblyFinal

Config60 sec.AssemblyConfig

Mech.& Test& Test

45 sec.AssemblyMech.

30 sec.Assembly

Welding

Welding

Operator Balance Chart - Part COperator Balance Chart - Part D

(Manual-Activated Arm)(Bar Code Diverter Piston)

180 sec.

150 sec.

140 sec.

Takt = 120 sec.Takt = 120 sec.

120 sec.

110 sec.

Elect.100 sec.Elect.

Assembly90 sec.90 sec.Assembly

Mech.

AssemblyFinalFinal

AssemblyConfigMech.AssemblyConfig

& TestAssembly& Test

40 sec.35 sec.

WeldingWelding

Operator Balance Chart - Part EOperator Balance Chart - Part F

(Bar Code Diverter Arm)(Sensor-Activated Piston)

180 sec.

Takt = 120 sec.Takt = 120 sec.125 sec.

105 sec.105 sec.

100 sec.Elect.90 sec.

Assembly85 sec.Elect.90 sec.

Assembly

Final

Mech.AssemblyConfigFinalConfig

45 sec.Assembly& TestAssembly& Test

40 sec.Mech.

WeldingAssembly

Welding

Operator Balance Chart - Part GOperator Balance Chart - Part H

(Laser Activated Piston)(Manually-Activated Piston)

200 sec.

150 sec.

140 sec.

130 sec.145 sec.


Elect.Elect.100 sec.100 sec.

AssemblyAssembly

Final80 sec.

AssemblyFinal

Mech.ConfigAssemblyConfig

Assembly& TestMech.& Test

35 sec.35 sec.Assembly

WeldingWelding

B-Charts-Future All Products




110 sec.110 sec.110 sec.110 sec.110 sec.110 sec.

100 sec.Final

Elect.Assembly

Assembly

Mech.Elect.Final

AssemblyAssemblyAssembly

Config.

& Test

65 sec.

Mech.Config.

AssemblyElect.& Test

Assembly

Final

Assembly

Welding

Welding





105 sec.

100 sec.

Elect.

Mech.AssemblyFinal

AssemblyMech.Elect.Assembly75 sec.Config.

AssemblyAssembly& Test

FinalConfig.

Assembly& Test

Final

Elect.Assembly

Assembly

WeldingWelding

Mech.Elect.

AssemblyAssembly

`




110 sec.110 sec.110 sec.110 sec.110 sec.

105 sec.

100 sec.

Config.

& Test90 sec.

Mech.Elect.Mech.

AssemblyAssemblyFinalAssemblyConfig.

Assembly& Test

Elect.

Assembly

Final

Assembly

Welding

Elect.

AssemblyWelding

Elect.

Assembly

Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H




105 sec.

100 sec.100 sec.

Final

Assembly

Mech.Elect.Mech.Final

AssemblyAssemblyAssemblyAssembly

FinalElect.Config.


Elect.

Assembly

Mech.

AssemblyConfig.Welding

Welding& Test



(CURRENT STATE)


A45603090140130110605405

B30603060140100110530330

C40604512015090100605400

D35603090180140110645445

E456060100180105105655430

F406030851259090520340

G356030150130140200745455

H35603080145100100550360

CUSTOM456030120160105110630430


(FUTURE STATE)


A357511010011043032026.56%

B25501209011039528515.79%

C301001108510042532523.08%

D30901601251105154059.88%

E40751407510543533030.30%

F358012085904103206.25%

G301351301402006354354.60%

H30701259510042032012.50%

CUSTOM35901109011043532532.31%




140 sec.140 sec.


110 sec.110 sec.

100 sec.

90 sec.Elect.Elect.


AssemblyFinal


Mech.& Test& Test


30 sec.Assembly

Welding

Welding



180 sec.

150 sec.

140 sec.


120 sec.

110 sec.



Mech.

AssemblyFinalFinal



40 sec.35 sec.

WeldingWelding



180 sec.


105 sec.105 sec.



Assembly

Final



40 sec.Mech.

WeldingAssembly

Welding



200 sec.

150 sec.

140 sec.

130 sec.145 sec.



AssemblyAssembly

Final80 sec.

AssemblyFinal




WeldingWelding






100 sec.Final

Elect.Assembly

Assembly

Mech.Elect.Final


Config.

& Test

65 sec.

Mech.Config.


Assembly

Final

Assembly

Welding

Welding





105 sec.

100 sec.

Elect.

Mech.AssemblyFinal



FinalConfig.

Assembly& Test

Final

Elect.Assembly

Assembly

WeldingWelding

Mech.Elect.

AssemblyAssembly

`





105 sec.

100 sec.

Config.

& Test90 sec.

Mech.Elect.Mech.

AssemblyAssemblyFinalAssemblyConfig.

Assembly& Test

Elect.

Assembly

Final

Assembly

Welding

Elect.

AssemblyWelding

Elect.

Assembly

Operator Balance Chart - Part G200 sec.Operator Balance Chart - Part H




105 sec.

100 sec.100 sec.

Final

Assembly

Mech.Elect.Mech.Final

AssemblyAssemblyAssemblyAssembly

FinalElect.Config.


Elect.

Assembly

Mech.

AssemblyConfig.Welding

Welding& Test



(CURRENT STATE)


A45603090140130110605405

B30603060140100110530330

C40604512015090100605400

D35603090180140110645445

E456060100180105105655430

F406030851259090520340

G356030150130140200745455

H35603080145100100550360

CUSTOM456030120160105110630430


(FUTURE STATE)


A357511010011043032026.56%

B25501209011039528515.79%

C301001108510042532523.08%

D30901601251105154059.88%

E40751407510543533030.30%

F358012085904103206.25%

G301351301402006354354.60%

H30701259510042032012.50%

CUSTOM35901109011043532532.31%




140 sec.140 sec.


110 sec.110 sec.

100 sec.

90 sec.Elect.Elect.


AssemblyFinal


Mech.& Test& Test


30 sec.Assembly

Welding

Welding



180 sec.

150 sec.

140 sec.


120 sec.

110 sec.



Mech.

AssemblyFinalFinal



40 sec.35 sec.

WeldingWelding



180 sec.


105 sec.105 sec.



Assembly

Final



40 sec.Mech.

WeldingAssembly

Welding



200 sec.

150 sec.

140 sec.

130 sec.145 sec.



AssemblyAssembly

Final80 sec.

AssemblyFinal




WeldingWelding






100 sec.Final

Elect.Assembly

Assembly

Mech.Elect.Final


Config.

& Test

65 sec.

Mech.Config.


Assembly

Final

Assembly

Welding

Welding





105 sec.

100 sec.

Elect.

Mech.AssemblyFinal



FinalConfig.

Assembly& Test

Final

Elect.Assembly

Assembly

WeldingWelding

Mech.Elect.

AssemblyAssembly

`



Takt = 120 sec.Takt = 12

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