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Creating Connected Process Flow

MHR 5350

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Just-in-Time

Right part

Right amount

Right time

Right place

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One-piece Flow

Products are processed and moved directly to the next process one piece at a time

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“Flow where you can.

Pull where you can’t.

Don’t Push!”

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Flow Continuum

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Process A Process B Process C End User

Elapsed time:33 seconds

Push – Batch & Queue

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Process A Process B Process C End User

Elapsed time:15 seconds!

Pull – Continuous Flow

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Tools to Establish One-Piece Flow

Pull techniques Supermarkets/Kanban Sequenced Pull

Workplace/Cell design

Clearly defined customer/supplier relationships

Visual controls

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Pull

Defined agreement with specified limits pertaining to Volume of production Model mix Sequence of model mix

Dedicated

Controlled

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Pull Example: Simple Process

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Pull Example: Three Distinct Models

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Pull Example: High Product Variety

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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

In the Office…Flow issues?

“Stop and Go” TasksUseless Information (e.g., e-mails,

etc.)Designing features the customer

doesn’t needNot utilizing resources to their full

potential

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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.

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Kanban Uses

Instruction

Self control to prevent overproduction

Visual control

Reduction of managerial cost

Reduction of inventory

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Kanban Advantages

Processes connected

Eliminates excess inventory Floor space Wasted material during model changeover Boxes/bins/returnables

Potential problem: people

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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

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Kanban Example

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Kanban Example

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Kanban Example

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Kanban Example

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Think

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

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Advantages of One-Piece Flow

RAPID CONTINUOUS IMPROVEMENT

Build in quality

Increased flexibility

Higher productivity

Decreased floor space

Improved safety

Improved morale

Reduced inventory

Project Assignment Create current state map (45-60 minutes)

Present current state map

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Questions?