1 / 27

Creating Connected Process Flow

Creating Connected Process Flow. MHR 5350. Just-in-Time. Right part Right amount Right time Right place. One-piece Flow. Products are processed and moved directly to the next process one piece at a time. “Flow where you can. Pull where you can’t. Don’t Push!”. Flow Continuum.

inari
Download Presentation

Creating Connected Process Flow

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Creating Connected Process Flow MHR 5350

  2. Just-in-Time • Right part • Right amount • Right time • Right place

  3. One-piece Flow • Products are processed and moved directly to the next process one piece at a time

  4. “Flow where you can. Pull where you can’t. Don’t Push!”

  5. Flow Continuum

  6. Push – Batch & Queue Process A Process B Process C End User Elapsed time: 33 seconds

  7. Pull – Continuous Flow Process A Process B Process C End User Elapsed time: 15 seconds!

  8. Tools to Establish One-Piece Flow • Pull techniques • Supermarkets/Kanban • Sequenced Pull • Workplace/Cell design • Clearly defined customer/supplier relationships • Visual controls

  9. Pull • Defined agreement with specified limits pertaining to • Volume of production • Model mix • Sequence of model mix • Dedicated • Controlled

  10. Pull Example: Simple Process

  11. Pull Example: Three Distinct Models

  12. Pull Example: High Product Variety

  13. In the Office…Flow issues? Handoffs: Jobs moving through depts. (inbox) Waiting (Approvals, etc.) Transaction Waste Re-Invention Waste Lack of ‘System Discipline’ High Process and Arrival Variation System Over/Under-Utilization and Expediting Ineffective or Barriers to Communication Redundant Tasks “Stop and Go” Tasks Useless Information (e.g., e-mails, etc.) Designing features the customer doesn’t need Not utilizing resources to their full potential

  14. Kanban • Signal/Sign/Card • Visual control system used to trigger activity in upstream process • Replenishment for production and material • Usually printed card • Part number/description • Quantity • Location • Picture • Etc.

  15. Kanban Uses • Instruction • Self control to prevent overproduction • Visual control • Reduction of managerial cost • Reduction of inventory

  16. Kanban Advantages • Processes connected • Eliminates excess inventory • Floor space • Wasted material during model changeover • Boxes/bins/returnables • Potential problem: people

  17. Kanban Rules • Downstream process should withdraw the right parts from the upstream process at the right quantity and right time • Upstream process should produce the parts in the quantities withdrawn by the downstream process • Defective products should never be transported to the downstream process • Number of kanbans should be minimized • Kanban can be utilized to adapt to small variation in production volume • Actual quantity of parts in bin/box/pallet must be equal to the quantity on kanban

  18. Kanban Example

  19. Kanban Example

  20. Kanban Example

  21. Kanban Example

  22. Think • If some problem occurs in one-piece flow manufacturing then the whole production line stops. Why is that a good thing?

  23. Advantages of One-Piece Flow • RAPID CONTINUOUS IMPROVEMENT • Build in quality • Increased flexibility • Higher productivity • Decreased floor space • Improved safety • Improved morale • Reduced inventory

  24. Project Assignment • Create current state map (45-60 minutes) • Present current state map

  25. Questions?

More Related