53-lean manufacturing implementation for upholstery frames

7/31/2019 53-Lean Manufacturing Implementation for Upholstery Frames

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Discrimination Policy Statement

The work upon which this project is based was funded in whole or in partthrough a grant awarded by the Wood Education and Resource Center,Northeastern Area State and Private Forestry, U.S. Forest Service.

In accordance with Federal Law and U.S. Department of Agriculturepolicy, this institution is prohibited from discriminating on the basis of race,color, national origin, sex, age, or disability. (Not all prohibited bases applyto all programs.)

To file a complaint of discrimination, write USDA, Director, Office of CivilRights, Room 326-W, Whitten Building, 1400 Independence Avenue, SW,Washington, DC 20250-9410 or call (202) 720-5964 (voice and TDD).USDA is an equal opportunity provider and employer.


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USFS Under Utilized Species Project

Supports Using Minor Hardwoods in the Eastern USForest for Making Upholstery Furniture Frames

Species Include Beech, Sycamore, Black Gum, SweetGum, Tupelo, Wormy Red Maple and Hackberry

All Under $500 Per Thousand Board Feet for Green

Lumber in Truck Load Quantities = Utility Grade Prices

These Species Offer Great Economy for Lumber andPlywood Frames


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Lean Manufacturing Attempts to Changethe Company Culture for Improvement

Common Company Unity Goals

Continuous Improvement Over Time

Consistent Monthly and Yearly Profitability

A Regular Look for Inefficiency and Waste

Empowerment of All Employees at All Levels


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We May Have More Positive UpholsteryFurniture Stories Coming in the Future

Legacy Furniture Recently WrittenUp in the Charlotte Observer

Conover Location

Small Manufacturer, 35 Employees

See Handout for the Article

Medical Furniture


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Lean Manufacturing is Really aBusiness Improvement Technique

Improvements Based On: Faster Delivery Time Less Inventory $ Investments

Reduced Waste of All Types Better Product Quality Improved Labor Productivity Reduced Factory Overhead Costs Improve Business Competitiveness

LM Has Many Similarities to the Better/Faster/Cheaper Concepts


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LM Impacts Monthly Income Statement

Revenues = Sum of $Price x Quantity

Expenses:

Materials Direct Labor Factory Overhead General, Sales and Administrative Overhead

Think Like a Boss and Understand the MonthlyProfit and Loss Statement = Income Statement!


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With No Lean Manufacturing Applied

Sales Units/Mo Fraction $/Unit $/Month

1,000 1.000 $400 $400,000

ExpensesMaterials 0.400 $160,000

Direct Labor 0.220 $88,000

Factory Overhead 0.330 $132,000 $380,000

Operating Profit $20,000

% Profitability on Sales 5.0%

Example P & L-Current Performance


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With Lean Manufacturing Applied

Sales Units/Mo Fraction $/Unit $/Month

1,050 1.05 $400 $420,000

Expenses (5% Improvement)

Materials 0.380 $159,600

Direct Labor 0.209 $87,780

Factory Overhead 0.314 $131,670 $379,050

Operating Profit $40,950

% Profitability on Sales 9.8%

Example P & L-5% Improved Performance


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LM Materials Improvement

Use Lower Cost Materials

Improve Material Yields

Reduce $Inventory Investment

Reduce Waste for Remakes and Repairs

Visual Scheduling System Can Reduce Overproduction


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Direct Labor Improvement

Can Reduce the Need for Specialized Labor

Improve Employee Effectiveness and Efficiency

Reduce Waste of Rework and Repairs

Visual Scheduling System Empowers Employees

Twin Table CNC Routers

Can Grow Labor Productivity


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Factory Overhead Improvement

Reduce the Need for Supervision and Management

Reduce Inventory and Supplies $

Reduce Floor Space Requirements

Simpler Equipment Can Be Less Expensive

Information Board is for theRough Mill Crew to Know the CompanysSchedule and Their Performance Levels


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Apply LM Concept forLumber and Plywood Frames

Pull

Flow

Perfection

Elimination of Waste

Five Ss


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Implement the 5 Ss Everywhere

Warehouses and Supply Rooms Production Work Centers Offices

1. Sort2. Set in Order

3. Shine andInspect4. Standardize5. Sustain


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Value Stream Mappingfor Lumber and Plywood Frames

Create a Process List of the Processing Steps

Classify Each Step as Processing, Wait, Storage,Inspection, Etc.

Identify the Communications Needed by the Crew toProcess the Frames

Include Purchasing, Design ,Engineering


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Exposed Wooden Frames

May Show Arms, Backs, Legs

Wood Species Must Have GoodFinishing Attributes

Can Connect to Lumber and

Plywood Interior Parts


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Frame Makers Can Include Lumberand Plywood in Their Frame Designs

Curved Parts Come From LumberGlued Up Panels That AreBandsawn or Plywood CNC

Machined

Can Use a CNC Band Saw forLumber Edge Glued Panels


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LM Frame Designer

A Frame Designer Can-

Work on a PC Linked to Others

Use Modeling Software

Link to Sales and Customers

Can Become a Active Agent toGrow Sales and Profitability = a

Team Player!


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Frame Designer/Engineer = a Star

Can Support Sales to Quickly Create Concept Models

Can Quickly Get Modified Products Into Production

Can Provide Ideas to Meet the Needs of Customers

Companies Need to Tap the Resources Now Available in

the Design/Engineering Department to Grow CompanySuccess


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Flow Chart for aLumber Frame That

is Modified From anExisting Unit

Sales & Marketing

Design & Engineering ModifyExisting

Unit

Purchasing & Creates& Production Control New

Unit

Rough Mill

Ripping & Chop

Machine RoomMultiple Machines

(Trim/Bore/Dowel/Notch)

Frame Assembly

Finishing

Upholstery Dept


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Applying LM for Lumber Frames

Think of Standardizing Rip Widths of Parts

Can Stock Lumber Rip Strips Ready to Process

Set Up Cellular Trim, Bore, Dowel and Notch WorkCells for Fast Processing of Small Order Quantities

Can Order Rough

Lumber Sorted toStandard Widths for

Better Rip Yields


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LM Layouts for Lumber Frames

Tie All Operations Together With Conveyors to

Eliminate Non-Value Added Labor and Time Delays

Can Use Manual Equipment With Fixtures for FastSetups and Changeovers

Scheduling is Important to Reduce Frames Waitingfor the Upholstery Department

Conveyors Between WorkCenters Can Eliminate LaborWasting Pallet Jacks andShop Trucks


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VSM Example forPlywood Frame

Goal is to LinkDirectly From the

Designers Softwareto the CNC Router,

Eliminate AnyAdditional Machining,Then Go Directly to

Assembly

Example Flow Chart for a Plywood Frame

Sales & Marketing

Design & Engineering Modify

Existing

Unit

Purchasing & Creates& Production Control New

Unit

CNC Machining

Frame Assembly

Finishing

Upholstery Dept


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LM Layouts for Plywood Frames

Recent Advances in Plywood

Frame Design Can LimitMachining to One Trip to a CNCRouter

Material Handling at the CNCRouter Becomes Very Important

Scheduling the Cutting of

Frames is Also Very Important

A 3-D Model of aPlywood Frame


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LM Advances for All Frames

Must Look at How to BetterSupport the Later UpholsteryOperations

Transportation to theUpholstery Shop

Finishing

Spring Up

Spring Cover Fabrics A 3-D Model of aPlywood Frame


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Management Linksto Lean Manufacturing

Managers Must Move to Open Management Methods

Managers Have to Devote Time to Meetings

Managers Have to Relate Company Goals to LM Efforts

LM Requires BossesWith Great Personal Skills


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Linking Lean Manufacturingto Company Goals

LM Supports Fast Responses to Customer Demands

LM Supports Low Inventory Investment

LM Supports Lower Factory Overhead

LM Can Support Significantly Higher Profitability


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Selling LM to Fellow Employees

Want Top Management to Appeal to All Employees

Want Employees to Offer Improvement Ideas Anywherein the Company

Want to Offer Training Classes in LM to Any Employee

Performance of LM Projects Should Be Posted


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LM Success RequiresSupply Chain Support

Must Cooperate With Up Field Vendors

Must Cooperate With Down Field Vendors

Must Cooperate With Support Organizations

53-lean manufacturing implementation for upholstery frames

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