1、1TenantsofSinglePieceFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectsZeroDefects=0DefectsNot3.4ppmQuality,Quality,QualityDefectsaretheWorstKindofWaste7TypesofWasteDefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouches2BatchSingle Piece FlowFrom:The Toyota Production
2、 SystemBuilding Quality into the ProcessSingle Piece FlowThe next process is the customer never send defects!Sample Inspect catches Defect too Late When you Finally Find a Defect How many more do you have?Where are they in the process?What is the root Cause?Single Piece Flow catches Defects immediat
3、ely When you find a Defect You only have one You know where it occurred You Can find/Resolve the Root Cause immediately3Check,Do,VerifyCheck-The previous operators work.Do-Your work.Verify-That you did your work correctly.4ProcessInspectTransportTransportation is integrated into the production proce
4、ssvia automation e.g.,moving lineProcessInspectProcessInspectTransportProcessInspectTransportation is integrated into the production processvia human conveyance e.g.,Chaku-ChakuBuilding Quality into the Process2 ways to perform SPFThe next process is the customer never send defects!5Check,Do,VerifyG
5、ets you into Parts Per Million quality-When you verify your work,you catch 1 flaw in 100 parts.The next person checks your work and can catch 1/100 so thats 1/10,000.Then that person Verifies their work and can catch 1/100.Thats 1/1,000,000 errors that can get through.6Check,Do,VerifyEvery Customer
6、in a Process has:-a right to expect perfect material-an obligation to inspect the material before use.-an obligation to inform the previous step in the process of any problem.-an obligation to stop the process until any problem has been resolved.7Single piece or one piece flow is a means to primaril
7、y buildQuality into the process.This is achieved by establishing a taktTime,developing std work,and swip.The premise is that an Operator can only work on one piece at a time,and performs a Quick quality check on the CTQs of the process before movingThe part to the following process.If a defect is de
8、tected,JidokaIs enactedthe line is stopped,and immediate action is takenTo remediate the situation and take countermeasures to preventreoccurenceTakt timeStd workFlow:work(process)that is done in conjunction with or simultaneous to transportation8One Piece Flow The production is organized into a syn
9、chronous chain where each person has a balanced amount of work relative to his/her supplier and customer in the chain.As one person finishes their element,so do all.Work is then moved down the line synchronously.Every person is empowered to stop the production process if a reject is spotted.9Organiz
10、ationAreaSupervisorNew/RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work SheetTo:TurnsDPUsScope of OperationsFrom:Quality CheckSafety PrecautionStandard Work-in-Process#Lots of Standard Work-in-ProcessTakt/Rate TimeTotal Manual&Travel TimeMan/Travel TimeOperatorEnd FinishWeldEnd
11、FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeTubingCFM CellFern BissonnetteCell 6All PartsAll Tubes1 1Mech.CleanRaw materialWeld100/DayFPIX-RayEDM2nd Qtr.01EndFinishOutside Cell27-avg lot=6FlexFinished GoodsACTION WORKOUTgGEMS Global Production SystemThe next process is the customer never
12、 send defects!Check,Do,Verify10One Piece Flow Your customer is the next step in the process.Give to your customer,exactly what they need(1 item),exactly when they need it,done perfect every time.11Tenants of 1 pcs Flow Do Not Make Defects Do Not Pass Along Defects Do Not Accept DefectQuality,Quality
13、,QualityDefects are the Worst Kind of Waste12System of manufacturing in which the final process withdraws the parts it needs from the precedingprocess at exact timing intervals,in the exact standardized amount needed.Pull Production Methodology&SequenceDefinitionRef Material Presentation training fo
14、r explanation on Supermarket definition and use13End FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlexEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlexParts13456End FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanT
15、orchBrazeMech.CleanFlexEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeMech.CleanFlex789102Assembly LineCell or Chaku-Chaku lineSupplierMaterialInformationSupermarketEmpty containerFull containerLegend1Sequence/TimingPull Production Methodology&Sequence14JITJidokaeGPS for G
16、PCHeijunkaLevel LoadingSequencingFinding a balance between the volume of work that your organization needs to do and your capacityAdjusting a production schedule to meet unexpected changes in customer demandOrdering the production in such a fashion to achieve the desired TAKT for all itemstaken from
17、 memory Jogger15Leveled production meanslowering the peaks amongthe daily production volumesas much as possible and making the production flow smooth and unflucuating.In general,the more fluctuations you in the production flow,the more muda you end up having.That is because the capacity and capabili
18、ty of a line tends to be set at a level that meets the peak production demand rather than the average demand.If the production line produces only a single product,you may be able to reduce muda simply by adjusting the production schedule and staffing level.But if you want to produce consistently at
19、an average level where you have many different kinds of products to produce in a single line,you have to do the averaging not just in volume but in kinds as well.This way of averaging both volume and in kinds is called production leveling or heijunka in Japanese.Leveled ProductionAmount of products
20、that can be soldHEIJUNKAAverage by total volumeAverage by model16 Leveled Load Production Build to forecast Build to FG inv Build after order is received ALL components need to be stocked in RM An order from these products takes precedence over 1-2-3 products build this first!Use StocksBuild StocksT
21、AKT0102030405060708090%F1F1F1F1F1F1F2F2F2F2F2F2 TAKT TimeDetermined by PSI2Q3Q4QOk to Build to FGRepeatable ProductsNon-Repeatable Products350300250Total6531066398668877710876108951210104403025380705021701501301200220012000350300250Total653106639866887771087610895121010440302538070502170150130120022
22、001200017Need to Determine.How Much20 bulbs per dayWhat Kind15/60 Watts 5/100 WattsWhen5-60W,2 100W,5 60W,2 200W,5 60W,1 100W TAKTLevel Load MixLevel Load SequenceIf we were making light bulbs.QuarterlyWeeklyWeeklyFrequency6060606060100 1006060606060100 1006060606060100Takt Time=Operating time per d
23、ayProduction requirement per dayAssumptions:Machine Breakdown=0 hourSetup Change=0 hourDefect Rate=0%Takt Time EquationFor more information on TAKT Refer to JIT SectionQuick Example18Setting the production sequence of multiple TRAM RAC Types(Med Systems Product)This is data for 3 products,Model 1,Mo
24、del 2,and Model 3,are produced at GEMS.The chart displays the monthly production level,the daily production level(monthly divided by 30),and the Takt time for each product type.THEY ARE ALL PRODUCED ON THE SAME LINE.How can these units be built in a level production mode using this example?Model 1Mo
25、del 2Model 3Detailed Example 19Since these three products are on the same line,you will need to follow the sequence pattern of 1-2-1-3 in your production mix.By doing it this way you are able to level-load your production both in terms of quantity and types.#1 Prod 1#4 Prod 3#2 Prod 2#3 Prod 1REPEAT
26、Mixed Assembly LineProduction Sequence by Type0246810Prod 1Prod 2Prod 3ProductTakt Time0246810121416Prod 1/Prod 2Prod 1/Prod 3ProductsTakt TimeProd 3Prod 2Prod 1If produced in batches,only the Model 1s will meet Takt timesIf produced to a sequence,2 units will be produced in 2 Takt timesLets show ho
27、w we validate this20ModelLine TaktTakt/Cycle GraphPart-QuantityPart Router1327.57.57.5See Std Work Combo Sheet for example.One sheet is created for each operatorAdd RailsAdd BackplAdd 1 SpringAdd 3 SpringAdd CircuiAdd CircuiAdd CircuiAdd CircuiAdd RAC2 Add RAC 4 Add RAU Add RAU Apply Label Apply Lab
28、el Apply Label Aqpply Label 1XXXXXXXXX2XXXXXXXXX3XXXXXXXXXXSort By Volume02000400060008000100001233123413571946234524682833289434563579385545675678678982489991Part NumberQuantity00.20.40.60.81PercentageSCT=25SCT=40SCT=30766676138127.597.5Step No.Operation NameTimeManualAutoTravelProduction ReqdTakt/
29、Rate TimeManualAutoTravelWaitOrganizationAreaSupervisorNew/RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work Combination SheetTotalsOperation TimeSec()Min()Hr()112/6/02AMXShannonX-RayStation 1&2J.David1234567Check MotorIssue DHRInstall Gen.HousingInstall ClipsInstall Term.StripIn
30、stall/Wire LatchJumper Wire to Filter10203040506070809074T/T32105641032546463040XStep No.Operation NameTimeManualAutoTravelProduction ReqdTakt/Rate TimeManualAutoTravelWaitOrganizationAreaSupervisorNew/RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work Combination SheetTotalsOpera
31、tion TimeSec()Min()Hr()112/6/02AMXShannonX-RayStation 1&2J.David1234567Check MotorIssue DHRInstall Gen.HousingInstall ClipsInstall Term.StripInstall/Wire LatchJumper Wire to Filter10203040506070809074T/T32105641032546463040XStep No.Operation NameTimeManualAutoTravelProduction ReqdTakt/Rate TimeManua
32、lAutoTravelWaitOrganizationAreaSupervisorNew/RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work Combination SheetTotalsOperation TimeSec()Min()Hr()112/6/02AMXShannonX-RayStation 1&2J.David1234567Check MotorIssue DHRInstall Gen.HousingInstall ClipsInstall Term.StripInstall/Wire Lat
33、chJumper Wire to Filter10203040506070809074T/T32105641032546463040X21Takt Build Time=#of Operations*TaktActual Build Time=SCTModelTBTModelABTModelObjectives:Produce to Takt Time(understanding no 2 products will have the exact same ABT)The sum of the DTot is zeroEvery product is produce at least once
34、No product is produced twice in a rowCreate a product sequence where:Dtot=S(#of Units in sequence*D)Dtot=-5(#of 1s)+10(#of 2s)+0(#of 3s)0=-5(2)+10(1)+0(1)In each sequence will contain one Model 1,two Model 2s,and 1 Model 3)According to the rules the sequence must run:Model 1 Model 2 Model 1 Model 32
35、2Guiding Principles:GPS Level-loadingPurpose:To provide guidelines for developing the method and tools to level-schedule the shop floor.Key Elements of Level-schedulingnProduction units are stratified according to planned sales volume nThe production sequence combines both orders and forecastnSequen
36、ce is designed to achieve the combined TAKT time for all itemsnEliminating production rate variance is required to achieve TAKT timenOnly build high volume products(top 80%)to FG inventory,if orders are not available nFG inventory levels are NOT targeted,but a result of TAKT time&orders flownLower-level group items are NOT sequenced without firm ordersnHold RM components inventory only for low volume items.These are items that you cant build until you have an ordernFill orders first from FG,second WIP,&third sequence them(attach the order to the production plan)
