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1、Tenants of Single Piece FlowDo Not Make DefectsDo Not Pass Along DefectsDo Not Accept DefectsZero Defects = 0 Defects Not 3.4ppmQuality, Quality, QualityDefects are the Worst Kind of Waste 7 Types of Waste Defective Parts Over Production Inventory Motion Transportation Waiting Manual Touches1BatchSi
2、ngle Piece FlowFrom: The Toyota Production 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 Ca
3、use? Single Piece Flow catches Defects immediately When you find a Defect You only have one You know where it occurred You Can find/Resolve the Root Cause immediately2Check, Do, VerifyCheck - The previous operators work.Do - Your work.Verify - That you did your work correctly.3ProcessInspectTranspor
4、tTransportation is integrated into the production processvia 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 pro
5、cess is the customer never send defects !4Check, Do, VerifyGets 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
6、,000 errors that can get through. 5Check, Do, VerifyEvery Customer 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 h
7、as been resolved.6Single piece or one piece flow is a means to primarily 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
8、the process before movingThe part to the following process. If a defect is detected, JidokaIs enactedthe line is stopped, and immediate action is takenTo remediate the situation and take countermeasures to preventreoccurence1.Takt time2.Std workFlow: work (process) that is done in conjunction with o
9、r simultaneous to transportation7One Piece Flow The production is organized into a synchronous 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.
10、Every person is empowered to stop the production process if a reject is spotted.8OrganizationAreaSupervisorNew / RevPageofDateProduction LinePart NumberPart NameOperatorStandard Work SheetTo:TurnsDPUsScope of OperationsFrom:Quality CheckSafety PrecautionStandard Work-in-Process# Lots of Standard Wor
11、k-in-ProcessTakt/Rate TimeTotal Manual & Travel TimeMan/Travel TimeOperatorEnd FinishWeldEnd FinishWeldOrbital WeldHydro TestMarkMech.CleanTorchBrazeTubingCFM CellFern BissonnetteCell 6All PartsAll Tubes1 1Mech.CleanRaw materialWeld100/DayFPIX-RayEDM2nd Qtr. 01EndFinishOutside Cell27 - avg lot = 6Fl
12、exFinished GoodsACTION WORKOUTgGEMS Global Production SystemThe next process is the customer never send defects !Check, Do, Verify9One 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
13、.10Tenants of 1 pcs FlowDo Not Make DefectsDo Not Pass Along DefectsDo Not Accept DefectQuality, Quality, QualityDefects are the Worst Kind of Waste11System of manufacturing in which the final process withdraws the parts it needs from the precedingprocess at exact timing intervals, in the exact stan
14、dardized amount needed.Pull Production Methodology & SequenceDefinitionRef Material Presentation training for explanation on Supermarket definition and use12Parts13456789102Assembly LineCell or Chaku-Chaku lineSupplierMaterialInformationSupermarketEmpty containerFull containerLegend1Sequence / Timin
15、gPull Production Methodology & Sequence13JITJidokaeGPS for GPCHeijunkaLevel 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
16、 fashion to achieve the desired TAKT for all itemstaken from memory Jogger14Leveled 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 m
17、uda you end up having. That is because the capacity and capability 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 sched
18、ule and staffing level. But if you want to produce consistently at 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 l
19、eveling or heijunka in Japanese.Leveled ProductionAmount of products that can be soldHEIJUNKAAverage by total volumeAverage by model15 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 pr
20、ecedence over 1-2-3 products build this first !Use StocksBuild StocksTAKT% F1F1F1F1F1F1F2F2F2F2F2F2 TAKT TimeDetermined by PSI2Q3Q4QOk to Build to FGRepeatable ProductsNon-Repeatable Products16Need to Determine . . .How Much20 bulbs per dayWhat Kind15/60 Watts 5/100 WattsWhen5 -60W, 2 100W, 5 60W,2
21、200W, 5 60W, 1 100W TAKTLevel Load MixLevel Load SequenceIf we were making light bulbs. . . QuarterlyWeeklyWeeklyFrequency6060606060100 1006060606060100 1006060606060100Takt Time = Operating time per dayProduction requirement per dayAssumptions:1)Machine Breakdown = 0 hour2)Setup Change = 0 hour3)De
22、fect Rate = 0%Takt Time EquationFor more information on TAKT Refer to JIT SectionQuick Example17Setting the production sequence of multiple TRAM RAC Types (Med Systems Product)ProductMonthlyRequirementDailyRequirementTAKT TimeModel 1720 units24 units5 minModel 2360 units12 units10 minModel 3360 unit
23、s12 units10 minTotal1440 units48 units7.5 minThis is data for 3 products, Model 1, Model 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 SAM
24、E LINE.How can these units be built in a level production mode using this example? Model 1Model 2Model 3Detailed Example18Since 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 y
25、our production both in terms of quantity and types.# 1 Prod 1 # 4 Prod 3# 2 Prod 2# 3 Prod 1REPEATMixed Assembly LineProduction Sequence by TypeIf 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 how we validate t
26、his19ModelLine TaktTakt/Cycle GraphPart - QuantityPart Router1327.57.57.5See Std Work Combo Sheet for example. One sheet is created for each operatorSCT=25SCT=40SCT=30766676138127.597.520Takt Build Time= # of Operations * TaktActual Build Time=SCT130230330125240330ModelTBTModelABT1-52+1030ModelObjec
27、tives: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 onceNo 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 = -
28、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 321Guiding Principles: GPS Level-loadingPurpose: To provide guidelines for developing the method and tools to level-schedule the shop floor
29、. Key Elements of Level-schedulingnProduction units are stratified according to planned sales volume nThe production sequence combines both orders and forecastnSequence is designed to achieve the combined TAKT time for all itemsnEliminating production rate variance is required to achieve TAKT timenO
30、nly 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)22
