1 / 36

TPS Cells and Manufacturing System Comparisons T. Gutowski

TPS Cells and Manufacturing System Comparisons T. Gutowski. Ref; J T. Black Factory with a Future McGraw-Hill 1991, Chapters 2 & 4 “The Monument of Monuments” from Lean Thinking, Womack & Jones 1996 5 homework problems due Nov 13th. Topics. Operation of cell; Standard work

vidal
Download Presentation

TPS Cells and Manufacturing System Comparisons T. Gutowski

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. TPS Cells and Manufacturing System ComparisonsT. Gutowski Ref; J T. Black Factory with a Future McGraw-Hill 1991, Chapters 2 & 4 “The Monument of Monuments” from Lean Thinking, Womack & Jones 1996 5 homework problems due Nov 13th Version 2; 10/27/02

  2. Topics • Operation of cell; Standard work • Increase in production rate • Video of cells • L, l & W for cell; L=lW • Design of cell • Comparison with job shop and flow line Version 2; 10/27/02

  3. Cell Features • “Synchronized”, sequential production • Operator decoupled from individual machines • Operator integrated into all tasks • Goal: single piece Flow • Best with single cycle automatics, but can be done manually too Version 2; 10/27/02

  4. Machining Cell Operator moves part from machine to machine (including “decouplers”) by making traverse around the cell. Video Version 2; 10/27/02

  5. Walking segments - 10 Machining Cell 6 5 7 8 4 9 3 10 2 1 Version 2; 10/27/02

  6. Parts in the cell ~ 14 Machining Cell 7 8 9 6 10 11 5 14 12 4 13 3 2 1 Version 2; 10/27/02

  7. Standard Work for Cell Cell produces one part every 153 sec Note: machine time Max (MTj) < cycle time CT i.e. 120 < 153 Version 2; 10/27/02

  8. To increase production rate add 2nd worker WORKER 2 WORKER 1 Version 2; 10/27/02

  9. What is the production rate for this new arrangement? Check max(MTj) < CT Worker 1; 70 < 77 Worker 2; 120 >76 One part every 120 seconds Can we shift work off of the HM to reduce the cycle time? Version 2; 10/27/02

  10. WORKER 2 WORKER 1 Version 2; 10/27/02

  11. Standard Work for Worker #2 Cycle # 1 Cycle # 2 Operator waiting On machine Version 2; 10/27/02

  12. What is the new production Rate? Check max(MTj) < CT Worker 1; 70 < 77 Worker 2; 90 > 76 Hence Worker #2 will be waiting on Vertical Mill #2 Version 2; 10/27/02

  13. What is the new production Rate? • The new production rate is; one part every 90 sec • Pro and Cons; Worker “idle”, can’t speed up by adding additional worker • Design for flexibility make; Max(MTj) < CT/2 Version 2; 10/27/02

  14. Alternative solution add 2 HM’s A B WORKER 2 WORKER 1 Version 2; 10/27/02

  15. What did you think of the operator’s job in the video? See B&S Video Seeta cave, Ellora, India Version 2; 10/27/02

  16. TPS Cell and Little’s Law • L =l W, we know L and l, what is W? • Define System Boundaries • Follow part around the cell • Single operator case Version 2; 10/27/02

  17. Number of round trips; 13 Machining Cell 7 8 9 6 10 11 5 12 4 13 3 2 1 1989 + 150 = 2139 Version 2; 10/27/02

  18. By Little’s Law L = (13 + 1) X 150/153) + 13 X (3/153) = 13.98 rate, l = 1/153 W = 153 X 13.98 = 2139 Homework #1 Determine L,l & W For the 2 operator Systems Version 2; 10/27/02

  19. Designing a cell for the “Rod Support” Goal one part every 2.5 minutes • Material; Aluminum extrusion • Tolerance + 0.005”, except for the two 0.50” radius corners which have + 1/64” Version 2; 10/27/02

  20. Cellular Layout (One operator) Cold Saw Radial Arm Drill Press Belt Sander Drill Press Version 2; 10/27/02

  21. Cellular Layout (One operator) Note; Times in minutes Version 2; 10/27/02

  22. Cold Saw .32+.05/.72 Belt Sander .8+.05/.4 Drill Press .55+.05/.04 Cellular Layout (One operator) RA Drill Press .47+.05/.24 Walking time Version 2; 10/27/02

  23. Standard Work for Rod Support Cell Note; Times in Seconds Version 2; 10/27/02

  24. 2.810 Homework; #2 Increase the production rate for this cell to one part every minute #3 After reading “The Monuments of Monuments”, answer; a) Calulate the production rate for each system b) How many cells are required to replace the Blohm grinder? Version 2; 10/27/02

  25. Other Layouts Job Shop Flow Line FMS Version 2; 10/27/02

  26. Job shop (Small quantities, Aluminum block) Version 2; 10/27/02

  27. Job shop (Large quantities, Aluminum extrusion) Version 2; 10/27/02

  28. CNC production, aluminum block Version 2; 10/27/02

  29. Flow shop (Unbalanced work load) Version 2; 10/27/02

  30. Flow shop (Improved work load) Version 2; 10/27/02

  31. Comparison Version 2; 10/27/02

  32. Cost Calculation without considering Inventory holding cost Version 2; 10/27/02

  33. Cost for increasing production volume C = F + V N Version 2; 10/27/02

  34. Lowest variable cost unless you further balance the Flow Shop 2 Cost for increasing production volume Version 2; 10/27/02

  35. Results Version 2; 10/27/02

  36. 2.810 Homework ; #4 design cell for this part at one part every 7 minutes, #5 redesign for one part every 4 minutes Dimensions in inches, surface in micro-inches Version 2; 10/27/02

More Related