Lps04 llayout

8/13/2018 LEAN LAYOUT 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 LAYOUT        Plant layout Lean plan layout Cell Line Buffer & Supermarket Paper Kaizen Ergonomics 11 April 2003 Nguyễn Như Phong 8/13/2018 PLANT LAYOUT  Basic / traditional pLayout   Fixed position layout Not-fixed position layout   Process-oriented / Function layout Product-oriented layout Nguyễn Như Phong 11 April 2003 Plant layout  Arrangement of physical plant facilities   Fixed-position layout Product moving layout    11 April 2003 Process layout Product-flow layout Cell layout Nguyễn Như Phong 8/13/2018 Plant layout  Fixed-position layout  Product remain in one location,     because of size & weight Equipment & material used brought to it Project layout Associated w JS  Complex products fabricated in very low quantities Nguyễn Như Phong 11 April 2003 Plant layout  Process layout  Machines arranged into groups    Flexible advantage Different parts    according to general type of manu proc Unique sequence of operations Routed through the respective departments JS & BP 11 April 2003 Nguyễn Như Phong 8/13/2018 Plant layout  Product-flow layout    One product / class of product in large volume  Complex assembled  Long sequence of operations Facilities arranged efficiently Inflexible arrangement 11 April 2003 Nguyễn Như Phong Plant layout  Cell layout   GT layout Combine  the efficiency of product-flow layout  the flexibility of process layout 11 April 2003 Nguyễn Như Phong 8/13/2018 LEAN PLANT LAYOUT   The plant builds in waste many years Schonberger    green field length/breadth ratio = 60:40 for flexibility & flow Opportunity to question the VS map & interfacility spaghetti diagram 11 April 2003 Nguyeãn Nhö Phong Lean plant layout  Avoid too-big & unfocused plant    Max 400 people Several smaller focused plants,  each severving a particular cust Small focused self-contained factories  Own order entry,  production control,  dispatching,  meeting areas 11 April 2003 Nguyễn Như Phong 8/13/2018 Lean plant layout   Supplier on site Overall flow from one end the other     no backtracking multiple access points multiple loading docks max the no ext doors 11 April 2003 Nguyễn Như Phong Lean plant layout      Central MH spine some operations Grouping of inventory into supermarket Break up the VS map into pull segment / loops Avoid big warehouse Establish a series of specific water-spider routes 11 April 2003 Nguyễn Như Phong 8/13/2018 Lean plant layout  Avoid long line & conveyors    Use compact cells Think 3D Not get hooked on using old facilities  Better demolish & move 11 April 2003 Nguyễn Như Phong Lean plant layout  Locate design & engineering areas    close manufacturing Locate the PC in the middle of the plant floor Foster communication & visibility  by open layout 11 April 2003 Nguyễn Như Phong 8/13/2018 Lean plan layout design  Product family identification  Break the plant into lines & cells  Determine    what products made in each cell / line Line   11 April 2003 Used a class of products Not mixed products Nguyễn Như Phong Lean plan layout design  VS mapping  Gain the picture of the overall flow  VS broken up into stages / sub-cells  Important in case of shared resources / convergent operations   11 April 2003 Capacity need be checked Dedicated resources considered Nguyeãn Nhö Phong 8/13/2018 Lean plan layout design  Strategic issues considered  What cell objectives      Efficiency – cost Reduced leadtime Flexibility Combination Rajan Suri approaches   11 April 2003 Technical – calculations & waste elimination Managerial – understanding market & competitive advantage Nguyễn Như Phong Lean plan layout design  The length of the line / cell    depends on inter-station buffer inventory One product  nil desirable Mixed model   11 April 2003 Variable times & variation in mix Some inventory kept in buffer location Nguyễn Như Phong 8/13/2018 Lean plan layout design  Activity timings & sampling  Side-by-side activities  Separate m/c jobs/time from operator tasks/time  Operator – several m/c   Operator idle when m/c run – waste Timings taken each work element Nguyễn Như Phong 11 April 2003 Lean plan layout design  Activity timings & sampling  Work element first studied & broken down into       VA, NVA, NVAU Video at least 10 observation Take actual times, no allowance rest & delay Min 200 observations at random intervals 11 April 2003 Nguyễn Như Phong 10 8/13/2018 Line  Lines compared w static build    Huge productivity & time gains Big reduction in time space Big improvement in quality   Improved standardization & visibility Big gains in training & apprenticeship 11 April 2003 Nguyễn Như Phong Line  Lines   Pulse lines Moving lines 11 April 2003 Nguyễn Như Phong 23 8/13/2018 Line  Pulse lines    Long station CT, eg several days Use platform move bw fixed locations at a regular TT Small no items on the line 11 April 2003 Nguyễn Như Phong Line  Moving lines     Shorter station CT, eg several hours Move very slowly (mm/s) Continuously using a track / conveyor One / several products on the line 11 April 2003 Nguyễn Như Phong 24 8/13/2018 Line  Lines   Fed by supporting cells parts pulled Automotive style  Using broadcast schedule synchronize several lines 11 April 2003 Nguyễn Như Phong Line  Line set up steps   broadly the same as those used for a cell Calculate the TT   No stations in a PL Total time in a ML 11 April 2003 Nguyeãn Nhö Phong 25 8/13/2018 Line  Standard work packages  Much fully & some semi-standard works  PL  No operators / station   Simultaneous operations Technical considerations Nguyeãn Nhö Phong 11 April 2003 Line  Standard work packages  ML  No operators     Earlier / later stations    as cells Simultaneous operations Balance the operator work against the TT more fully / lightly loaded retain catch-up capacity Allowance uncertainty & complexity 11 April 2003 Nguyễn Như Phong 26 8/13/2018 Line  Standard locations & footprints tools & parts  Each station an own shadow board    Operators participate in    Great advantage Waste –free ergonomic micro-layouts developing own parts & equipment handling sys Keep frequently used tools & parts line-side 5S established Nguyễn Như Phong 11 April 2003 Line  Pull sys required parts    Pull as much as pos Use RRS / ABC classification sys Priority kanban sys & supermarkets   for supporting cells A& B parts   11 April 2003 Stored in a specially designed wheeled racks Moved the exact location JIT Nguyễn Như Phong 27 8/13/2018 Line  Progress signaling sys  Visibility –   line advantage ML  Marks on the floor  Light sys  Operators report & display completion Nguyễn Như Phong 11 April 2003 Line  Progress signaling sys  PL  Standard work elements     Loaded via cards on a H-like board Turn around when complete Pre-consider contingencies resulting in delays Unforeseen problem board & action sequence 11 April 2003 Nguyễn Như Phong 28 8/13/2018 Line  Planning sys  Work package    may vary preplanning st the TT constraint best done by a H-like manual capacity board  load up the individual standard work elements 11 April 2003 Nguyễn Như Phong BUFFER & SUPERMARKET  Building blocks    Workstations Buffer / Supermarket Layout & Building blocks – skeleton     Vision & strategy – eye & brain Hoshin deployment & measurement – nervous sys Q & improvement – muscular sys Giving energy & getting rid of waste – digestive sys 11 April 2003 Nguyễn Như Phong 29 8/13/2018 Buffer & Supermarket  Constraint / bottleneck A    feeding non-constraint B Buffer placed in front of A, not in front of B Buffer size  Sufficient ensure time coverage     11 April 2003 for frequent upstream disruption Not unusual events Include replenishment time parts on a pull sys Plus safety stock Nguyeãn Nhö Phong Buffer & Supermarket  Non-constraint B feeding constraint / bottleneck A Buffer placed in front of A, not in front of B   A & C feeding B, A-constraint, B&C-non Buffer placed in front of A, not in front of B on line AB In front of B on line CB,     Buffer placed if low cost items Synchronization arranged if costly items Parts passed the valuable constraint,   11 April 2003 delayed as little as pos Nguyễn Như Phong 30 8/13/2018 Buffer & Supermarket A feeding B&C,  A-long CO, B&C-little/no CO B&C work whenever required B&C work only periodically & one at a time    Nguyễn Như Phong 11 April 2003 Buffer & Supermarket  B&C work whenever required   Supermarket placed bw A and B-C B&C work only periodically & one at a time  Supermarket  avoided if A synchronized  needed in front of A   work on either part when called upon by B/C Priority/accumulation kanban sys  Indicate when buffers in front of B&C get too low  Target batch size ? 11 April 2003 Nguyễn Như Phong 31 8/13/2018 Buffer & Supermarket  Non-constraint B&C feeding constraint A Buffer in front of A B&C required make a part at A,   buffer at each  B&C separate     Synchronized scheduling (pull) sys Building inventory of B while A works on C & vv The priority (pull) sys B&C arranged accordingly Nguyễn Như Phong 11 April 2003 Buffer & Supermarket  Sequential operations   A constraint/near constraint in relation overall TT Process can be flowed  Especially      Treated as one cell Controlled by pull signal Supermarket / buffer  11 April 2003 One piece flow Pitch-time flow  Alternate different products every pitch increment only in front of the first & after the last Nguyễn Như Phong 32 8/13/2018 PAPER KAIZEN  Paper kaizen     activity done in a group as a theoretical / planning exercise remove waste & make improvement before trying it out real at Gemba The P in PDCA cycle 11 April 2003 Nguyễn Như Phong Paper Kaizen   Normally followed up by an exercise at Gemba  Card board sim  Actual implementation on the factory floor Usually undertaken w either the basic mapping tools  Current state  Spaghetti  Demand amplification  Q filter map 11 April 2003 Nguyễn Như Phong 33 8/13/2018 Paper Kaizen  Cell-based Paper kaizen  Calculation    TT & Cell CT (95% TT) Theoretical no operators Accumulating times against the target CT by each operator Nguyễn Như Phong 11 April 2003 Paper Kaizen  Cell-based Paper kaizen  Reduce the no operators       Reduce walk time Change the layout Remove as many as NV activities as pos Consider the possibility of auto eject & gravity feeds Think in 3D – inventory/tools stored on racks outputs    11 April 2003 A new layout diagram showing operator movement & standard inv A work balance chart / sketch A work combination sheet Nguyễn Như Phong 34 8/13/2018 Paper Kaizen  Activity sampling  Extend PK  Take out as much of the extra wastes   discovered as part of the sampling Eg more efficient organization/ communication    Extend the effective working time per day Increase the TT Reduce the no operators Nguyễn Như Phong 11 April 2003 Paper Kaizen  Activity sampling  Reveal waste in the actual operation cycles  Most of which eliminated  Various activities time  11 April 2003 reduced by appropriate percentage Nguyễn Như Phong 35 8/13/2018 ERGONOMICS   Good ergonomic essential any manufacturer Lean ergonomic  an extension of conventional ergonomics 11 April 2003 Nguyễn Như Phong Lean perspective on Ergonomics  Working on takt / rhythm    Standing rather than sitting Inverse relationship   A regular rhythm assist good blood circulation bw force exerted & duration of muscular contraction The best w/s allow height adjustment 11 April 2003 Nguyễn Như Phong 36 8/13/2018 Lean perspective on Ergonomics  Ergonomic 5S  Shadow board tools & parts    correctly located ergonomically Maintain a natural posture at all time See the progress of a ML  clearly marked by lights / time marking on the floor 11 April 2003 Nguyễn Như Phong Lean perspective on Ergonomics  TPM & Q related gauges, dials & displays    Design using ergonomic principles Eg Colour marked operating range Make use of visual warning devices  Eg Color stickers 11 April 2003 Nguyễn Như Phong 37