Lps09 fsm

8/13/2018 MAP THE FUTURE STATE 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 MAP THE FUTURE STATE  Lean application stages     Demand Flow Leveling Map the FS       Begin the FSM Focus on demand Focus on flow Focus on leveling Why maintaining takt image matters FSM Wrap up 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Lean application stages  Lean concepts grouped into stages     Demand Flow Leveling Tools, techniques within each stage 11 April 2003 GVC ThS Nguyễn Như Phong Lean application stages  Implement stages in the same order    Understand the stages of application Along w the guideline implementing VSM Give solid approach  Not only implementing But also sustaining lean improving 11 April 2003 GVC ThS Nguyễn Như Phong  8/13/2018 Lean application stages  The common principles / goals  Stabilize processes  Reviewing       cust demand, equipment capabilities Labor balance, Material flow Standardize processes Simplify through kaizen 11 April 2003 GVC ThS Nguyễn Như Phong Lean application stages  Demand   Understanding C demand Including Q characteristics, LT, price 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Lean application stages  Flow   Implementing continuous flow manu Inex cust receive  right prod  at the right time  in the right quantity 11 April 2003 GVC ThS Nguyễn Như Phong Lean application stages  Leveling    Distributing work evenly By volume & variety To  Reduce inventory  Allow smaller orders by the cust 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Understand cust ordering patterns  What need produce     Specifically in terms of quantity & delivery requirement Actual no parts need produce each day Understand cust ordering patterns Info sources       Sale forecasts Previous 3m’s production Current production forecasts Long-term agreement Cust interview What producing last & this week 11 April 2003 GVC ThS Nguyễn Như Phong Understand cust ordering patterns  opposite attitudes toward C demand   There is no tomorrow ! There is always tomorrow ! 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Understand cust ordering patterns  No tomorrow !    Meeting C demand takes more than just applying the appropriate tools Only today meet C’s expectations Always tomorrow !    Prevail in many org Can get most of it done today & finishing it tomorrow Achieving no better than 90% on time delivery 11 April 2003 GVC ThS Nguyễn Như Phong Demand  Tools & concepts  for determining & meeting demand       11 April 2003 Takt time Pitch Takt image Buffer & safety inventory FG market Lights-out manu GVC ThS Nguyễn Như Phong 8/13/2018 Takt time  Takt time   The pace of C demand The rate at which   Producing takt   A company must produce a product satisfy C demand Synchronizing the production pace w the sales pace Takt time = time / volume (s)  Available production time   Minus downtime: break, lunch, meeting, … Total daily quantity required 11 April 2003 GVC ThS Nguyễn Như Phong Operational Takt time  Operational Takt time   Time faster than takt time Used balanced the line accommodate a chronic sys failure    Equipment downtime Absenteeism Sudden C demand change  Eg 10% faster  Focus Kaizen activities reduce sys problems   T = 60 s  OTT = 54s Move toward the true C demand 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Pitch  The ideal state in any pull sys    Eliminate all waste Create one-piece flow through the entire sys Cust not order product one piece at a time  But in a standard pack-out quantity  Convert takt time into pitch  11 April 2003 Shipped in a container of some sort GVC ThS Nguyễn Như Phong Pitch  Pitch   The amount of time based on takt Required an upstream operation   11 April 2003 release a predetermine pack-out quantity of WIP a downstream operation GVC ThS Nguyễn Như Phong 8/13/2018 Pitch  Pitch = takt time * pack-out quantity     takt time – cust driven pack-out quantity – may not Eg: P = m/p * 20 p/c = 20 m High volume, low variety line: P=12 – 30 m 11 April 2003 GVC ThS Nguyễn Như Phong Pitch  Calculating pitch – a compromise bw    Producing in large batches Implementing 1p flow Not always practical produce takt one piece at a time   But possible produce a small batch in pitch Eg T = 0,5 s 11 April 2003 GVC ThS Nguyễn Như Phong 8/13/2018 Advantages of Pitch  Advantages of Producing in small batches  based on pitch      A forklift less necessary Improved safety Improved I control Problems identified immediately Much-shorter-time reaction a problem 11 April 2003 GVC ThS Nguyễn Như Phong Takt image    Visualize 1-p flow Strike for the ideal state of 1-p flow Takt image –  The vision of the ideal state     Eliminate waste Improve the VS performance Achieve OPF based on takt time Risk wo a clear takt image  Always tomorrow 11 April 2003 GVC ThS Nguyễn Như Phong 10 8/13/2018 Continuous flow  Recommendations  CD tools already present  5S   work on flow wo interrupting regular, timely deliveries address physical & psychological barriers change 11 April 2003 GVC ThS Nguyễn Như Phong Line balancing  LB  The process    evenly distribute the work elements within a VS in order meet takt time Help   11 April 2003 Optimize the use of personnel Balance the workload achieve a smoother flow GVC ThS Nguyễn Như Phong 55 8/13/2018 Line balancing  To balance a line    Review a current CTs & work element assignments Create an Operator Balance Chart OBC Determine the no operators needed NO = TCT / T   Plans the changes needed  balance the work among the target no operators Create FS OBC 11 April 2003 GVC ThS Nguyễn Như Phong PM CASE T = 55 s  TCT = 170 s  NO = 170 / 55 = 3.09   Machining Deburring Crimping Testing Marking NOO 1 1 CT (s) 45 40 30 50 CO (m) 60 5 11 April 2003 GVC ThS Nguyễn Như Phong 56 8/13/2018 PM CASE  Improving programming & tooling maintenance   Eliminate the need deburring Crimping & testing   operator CT = 70  55 s Machining & Deburring Crimping & Testing Marking NOO 1+0 =1 1+1 =  1 CT (s) 45 + = 50 40 + 30 = 70  55 50 11 April 2003 GVC ThS Nguyễn Như Phong PM CASE  Reducing CO  Machining:    60  15 m CO / shift  30 m/shift Crimping, testing, marking:  CO (m) 11 April 2003 5