Lps01 lproduction

8/13/2018 LEAN PRODUCTION GVC ThS Nguyễn Như Phong nguyenphong.bksg@gmail.com; www.isem.edu.vn Kỹ thuật Hệ thống Công nghiệp ĐH BÁCH KHOA – ĐHQG TPHCM (Tài liệu giảng dạy cho ISE) 2018 LEAN PRODUCTION   Production System Lean Production System 11 April 2003 Nguyễn Như Phong 8/13/2018 PRODUCTION SYSTEMS          Production Industries - Manufacturing industries Types of production Manufacturing functions Info processing Production organization Flows in manufacturing Effective manufacturing PS Performance Measure Nguyeãn Nhö Phong 11 April 2003 PRODUCTION  Production   Transformation process Convert RM into finished products   Value in the marketplace Product   Intangible – service Tangible – goods   11 April 2003 Discrete Continuous Nguyeãn Nhö Phong 8/13/2018 Difference bw services & goods Services Goods Output intangible Tangible Kept in stock No Yes Production & consumption simultaneous Delay Mass production not Possible Server – customer Interaction A lot Little / no 11 April 2003 Nguyễn Như Phong Difference bw services & goods C participation Facilities / factory C Resource Q measurement Q dependence Output measurement 11 April 2003 Services Goods Yes close Labor intensive Difficult On the server difficult no Far away Largely automated Easier Not on one person Usually Nguyễn Như Phong 8/13/2018 Production  Product made by a combination of      Manual labor Machinery Tools Energy Transformation process   Sequence of steps Each step   bring the material closer into the desired final state The individual step – production operations Nguyễn Như Phong 11 April 2003 INDUSTRIES  Industries   Service industries Goods industries  Manufacturing industries –   Process industries –  11 April 2003 discrete items continuous items Nguyễn Như Phong 8/13/2018 Manufacturing industries  types form a transformation chain  Basic producer   Converter   Natural resources  raw material RM  uncomplicated items Fabricator  fabricate & assemble the final product   11 April 2003 Produce component Assemble components into consumer goods Nguyeãn Nhö Phong TYPES OF PRODUCTION   According quantity of product made Types of production    Job shop production Batch production Mass production   11 April 2003 Quantity production Flow production Nguyễn Như Phong 8/13/2018 Types of production Job shop Batch production Mass production Production quantity Low volume, Small lot size, often one of a kind Medium-sized lot Eg 50 High volume Variety High Medium Low Production rate Low Medium High Labor skill level High Med Low Equipment Flexible & general purpose General purpose but designed high rate production Completely dedicated Special tooling Low Med High Plant layout Process Process / Product Product Purpose Meet specific cust orders Satisfy continuous cust demand High demand rate of a particular product 11 April 2003 Nguyễn Như Phong MANUFACTURING FUNCTIONS  Basic function to convert RM into FG      Processing Assembly Material handling & storage Inspection & test Control 11 April 2003 Nguyeãn Nhö Phong 8/13/2018 Processing operations  Transform the product     from one state of completion into a more advantage state of completion No materials / components assembled / added Energy added to  Change the shape  Remove material  Alter physical properties 11 April 2003 Nguyễn Như Phong Processing operations  categories     Basic processes Secondary processes Operations enhance physical properties Finishing operations 11 April 2003 Nguyễn Như Phong 8/13/2018 Processing operations  Basic processes  Give the work material initial form  Eg    Metal casting, plastic molding Secondary processes  Give the work part the final desired geometry  Eg   Turning, drilling, … Nguyễn Như Phong 11 April 2003 Processing operations  Operations to enhance physical properties    Physical properties improved Eg Heat treating Finishing operations  Improve the appearance  Eg     11 April 2003 provide the protective coating on the work part Painting, polishing, plating Nguyeãn Nhö Phong 8/13/2018 Processing operations  Manufacturing process  Inputs       RM Equipment Tooling, fixture Energy Labor Outputs   Completed work piece Scrap & waste Nguyễn Như Phong 11 April 2003 Assembly     Follow the processing operations Assembly & joining processes / more components joined together Eg  Mechanical fastening   screw, nut, rivets, … Joining processes  welding, brazing, soldering 11 April 2003 Nguyễn Như Phong 8/13/2018 Material handling & storage  Moving & storing materials     bw processing & assembly operations More time to move & store than to process Majority of labor cost As efficiently as pos Nguyễn Như Phong 11 April 2003 Inspection & test   Part of QC Inspection  Whether the manufactured product meets    the established standards & specifications Test concerned with  functional specification of the final product 11 April 2003 Nguyễn Như Phong 10 8/13/2018 MEASURE OF PERFORMANCE MLT MCT Production rate Operation time Capacity Utilization & Availability WIP TIP         11 April 2003 Nguyeãn Nhö Phong LEAN PRODUCTION SYSTEMS    Lean Chronology What is Lean ? The Toyota Production System – TPS 11 April 2003 Nguyễn Như Phong 29 8/13/2018 LEAN CHRONOLOGY   1893 F.W Taylor begins work as consulting engineer 1896 Vilfredo Pareto   publishes law of economic distribution 1909 Frank & Lillian Gilbreth  study bricklaying beginning of motion study  1911 Wilson EOQ formula 1913 Ford establishes Highland Park plant  1922     using the moving assembly line Toyoda Sakichi, develops automated loom Gantt The Gantt chart: a working tool management 11 April 2003 Nguyễn Như Phong Lean Chronology   1931 Walter Shewhart 1st book on SPC & PDCA 1936 Toyota Motor Corporation   1941 War break out   spun off from Toyoda Automatic Looms Comp Toyota forced suspend new JIT sys 1945 Shigeo Shingo  presents concept of production as a network JMA 11 April 2003 Nguyeãn Nhö Phong 30 8/13/2018 Lean Chronology    1949 Taiichi Ohno takes up cause of JIT 1951 Juran handbook of QC 1961    Shigeo Shingo devises & defines Pokayoke Ishikawa devises Quality Circle Feigenbaum, TQC, McGrawHill 11 April 2003 Nguyễn Như Phong Lean Chronology        1969 Shigeo Shingo – QCO –SMED 1971 JIT quite refined & fully operational 1773 Oil crisis hits TPS widely copied in Japan 1975 Orlicky, MRP, McGrawHill 1978 first articles on JIT 1981 Motorola sigma methodology 1983 Hall, Zero Inventory, Monden, TPS 11 April 2003 Nguyeãn Nhö Phong 31 8/13/2018 Lean Chronology  1985 SMED, Productivity 1986 Maasaki Imai, Kaizen 1988 Nakajima, TPM; Akao, QFD 1989 Ohno, Kanban – JIT in Toyota 1990 Womack & Jones,  1996 Womack & Jones,  1999 Rother & Shook,  2002 Womack & Jones,         “The machine that changed the world”, Rawson “Lean thinking”, Simon &Schuster “Learning see”, Lean enterprise institute “Seeing the whole”, Lean enterprise institute Nguyễn Như Phong 11 April 2003 WHAT IS LEAN ?  Waste prevention  More about waste prevention than waste elimination  Non lean –  resolve inefficiencies  Beginning lean –  Experience lean –   11 April 2003 solve problems remove waste dissolve waste Nguyễn Như Phong 32 8/13/2018 What is Lean ?  Value  Leaner go after waste  Waste elimination & prevention   half of the total picture Rethinking the value side  as least as important  lead seeking out new opportunities Nguyeãn Nhö Phong 11 April 2003 What is Lean ?  System  More than the sum of its component  Constant interplay w environment   Adapt continuously    not obvious boundary but at a faster rate when threaten Evolve Lean learn   11 April 2003 to recognize & kill off inappropriate tools whilst developing new & stronger ones Nguyễn Như Phong 33 8/13/2018 What is Lean ?  System  Human body analogy       Skeleton – layout, supermarket, buffer Circulation sys – Kanban, material Eyes & brain – vision & strategy Nervous sys – control, deployment, measurement Muscular sys – quality & improvement Digestive sys – energy & getting rid of waste Nguyễn Như Phong 11 April 2003 What is Lean ?  Process  In terms of  not optimizing function / department  but end2end values stream  integration of    11 April 2003 marketing – sales – design – engineering – manufacture – distribution – service tie together by info Nguyễn Như Phong 34 8/13/2018 What is Lean ?  Process  The closer the cust.,    Different type of organization   the quicker the response, the better Different structure, measures, careers Perfect process   Every step – valuable, capable, available, adequate All steps linked by flow, pull, leveling 11 April 2003 Nguyễn Như Phong What is Lean ?  Lean is at the Core      Agile APS SIGMA TOC Manufacturing strategy 11 April 2003 Nguyeãn Như Phong 35 8/13/2018 TPS Nguyễn Như Phong 11 April 2003 The pillars of the TPS  TPS   Lean manufacturing Goal - Eliminate waste to achieve the     Highest quality Lowest cost Shortest lead time pillars   11 April 2003 JIT production Jidoka Nguyễn Như Phong 36 8/13/2018 The pillars of the TPS  TPS  Foundation - People   Play the role of eliminating wastes Encouraged to make positive contributions   toward improving work areas Kaizen events   Analyze conditions Recommend & implement improvements Nguyễn Như Phong 11 April 2003 JIT production  Continuous flow production  The ideal state of continuous flow  characterized by ability to replenish a single part  One piece flow   Goal provide cust w the highest quality prod  meeting highly specific order & delivery requirement     pulled by the cust only those units ordered just when needed exact amount needed In-ex cust in the VS 11 April 2003 Nguyễn Như Phong 37 8/13/2018 JIT production  Tools      VSM I, Takt time, Standardized work, Kanban, Supermarket … 11 April 2003 Nguyễn Như Phong Jidoka  Autonomation –  The use of automation to     automation w a human touch mistake-proof the detection of defects free up workers perform tasks within work cell promote a smooth, defect-free proc flow 11 April 2003 Nguyễn Như Phong 38 8/13/2018 Jidoka  Goal – zero defects  Never pass a defective prod Downstream   Promote flow within a JIT sys Eliminate the risk  undetected defect end up in hands of customer Nguyễn Như Phong 11 April 2003 Jidoka  Accomplished slowly, systematically, inexpensively  machine only VA work  reduces cycle time  eliminate wastes of     11 April 2003 waiting, transport, inspection, defects Nguyễn Như Phong 39 8/13/2018 Jidoka  functions     Separate human work from machine work Develop defect-prevention devices Apply jidoka assembly operations The concepts & tools behind   poka-joke – mistake proofing sigma 11 April 2003 Nguyễn Như Phong The 14 Toyota Way Principles  Base management decisions on a long term philosophy,      even at the expense of short term financial goals Create continuous flow to bring problems to surface Use pull system avoid overproduction Level out workload – Heijunka Build a culture of stopping to fix problems,  get quality right the first time 11 April 2003 Nguyễn Như Phong 40 8/13/2018 The 14 Toyota Way Principles  Standardized task –  foundation for CI & employee empowerment  Visual control, no problem hidden Only reliable, thoroughly tested technology Grow leaders thoroughly understand the work,  Exceptional peoples & teams     live the philosophy, teach it others follow company philosophy 11 April 2003 Nguyễn Như Phong The 14 Toyota Way Principles  Respect extended network of partners & supply      by challenging & helping Go & see thoroughly the situation Make decisions thoroughly by consensus, implement decisions rapidly Becoming a learning organization  through relentless reflection & CI 11 April 2003 Nguyễn Như Phong 41 8/13/2018 LP Papers in www.isem.edu.vn 10 11 12 A Changeover Time Reduction through an integration of lean practices 37 A comparative study of POLCA and generic CONWIP PC systems in erratic demand conditions 49 A hybrid push/pull control algorithm for multistage,multi-line production systems 05 An Account for Implementing Just-in-time: A Case Study of the Automotive Industry A lean production control system for high-variety/low-volume environments 42 An approach to improve the PCE and reduce the LT of a Mango Juice Proc Line by using lean tools 50 A New Concept of Cellular Manufacturing 33 Application of JIT Manufacturing Concept in Aluminium Foundry Industry in Zimbabwe 08 Application of LM to Higher Productivity in the Apparel Industry 51 Application of LM to Improve the Performance of Health Care Sector in Libya 03 Application of LM Principles To The Financial Services Sector 02 Application of LM Tools in the Food and Beverage Industries 30 Friday, April 11, 2003 Nguyễn Như Phong LP Papers in www.isem.edu.vn 10 11 12 Application of Lean Strategy to Redesign the Assembly Process Flow of Glow Plug Application of Kanban System For Managing Inventory 09 Application of Kanban System For Implementing Lean Manufacturing 14 A Primer: LM Applications for the Semiconductor Industry 18 A View On CONWIP Control Policy In Supply Chain Using Heuristic Method 38 Cellular Lean Model to Reduce WIP Fluctuation in Garment Manufacturing 13 COT Reduction and Productivity Improvement by Integrating SMED w Impl of MES for better PPC 41 Development of Kanban System at Local Manufacturing Company 32 Impact of Changeover time on productivity 34 Implementation of JIT Production through Kanban System 15 Implementation of a Cellular Manufacturing Tool for Minimization of NVA Activities 46 Implementation of LM through Supplier Kaizen Framework 29 Friday, April 11, 2003 Nguyễn Như Phong 42 8/13/2018 LP Papers in www.isem.edu.vn 10 11 12 Implementation of LM Through The Technique of SMED to Reduce CTO Implementation of Kanban System For Inventory Tracking & Establishing Pull Production 31 Improvement Of PCE By Implementing A Lean Practice 35 Improving the productivity of sheet metal stamping subass area using the application of LM principles 26 Improving Production Performance through Lean Manufacturing Techniques in a Manufacturing Firm 48 JIT Approach In Inventory Management 12 Kanban Applied To Reduce WIP In Chipper Assembly For Lawn Mower Industries Kanban System in Automobile Industries 22 Lean Hospitality - Application of Lean Management methods in the hotel sector 47 Lean Inventory Management in the Wood Products Industry 04 Lean Production And Manufacturing Performance Improvement In Japan, UK & US LM Implementation in the Assembly shop of Tractor Manufacturing Company 39 Friday, April 11, 2003 Nguyễn Như Phong My LP Case Studies in www.isem.edu.vn Xây dựng hệ thống Sản xuất tinh gọn cho công ty DMDA 2007 Lương Quý Tuấn Anh K2002 Xây dựng hệ thống Sản xuất tinh gọn cho công ty Juki VN 2007 Mai Thiên Ân K2003 Xây dựng hệ thống Sản xuất tinh gọn cho công ty Kyoshin VN 2008 Nguyễn Quang Tuấn K2003 Xây dựng hệ thống Sản xuất tinh gọn cho công ty SEE-Hưng Long 2009 Nguyễn Duy, Nguyễn Thiên Kim K2004 Xây dựng hệ thống Sản xuất tinh gọn cho cơng ty Sonion VN-EMC 2009 Lê Thúc Hồng, Nguyễn Hồng Tiến, Lê Gia Điền K2004 Ứng dụng tư tinh gọn cải tiến Hệ thống dịch vụ cho ISED I 2009 Đỗ Thị Kim Tiền, Lu Tùng Thanh K2004 Ứng dụng tư tinh gọn cải tiến Hệ thống dịch vụ cho ISED II 2010 Hồ Thị Phương Dung, Đặng Hữu Thành K2005 Friday, April 11, 2003 Nguyễn Như Phong 43