factory layout design 5s workplace organisation · - facility layout design - 5s workplace...
TRANSCRIPT
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BRIAN SAINSBURY / ROMAN ZAHHAROV 08/02/12
Overview for T-Tammer
• FACTORY LAYOUT DESIGN 5S WORKPLACE ORGANISATION
- FACILITY LAYOUT DESIGN - 5S WORKPLACE ORGANISATION
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Agenda
•5S workplace organization
•Facility layout design
•Summary
15 May 2012
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Agenda
•5S workplace organization –introduction
–pilot overview and before / after
–conclusions / further steps
•Facility layout
•Summary
15 May 2012
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Agenda
•5S workplace organization –introduction
–pilot overview and before / after
–conclusions / further steps
•Facility layout
•Summary
15 May 2012
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5S Workplace Organization and
Standardization
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Agenda • Introduction to 5S
– Sort / SORTEERI
– Set-in-order / SEA KORDA
– Shine / SÄRA – Standardize / STANDARTISEERI
– Sustain / SÄILITA
• 5S and other Building Blocks of Lean
• A model for implementation
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Agenda • Introduction to 5S
– Sort / SORTEERI
– Set-in-order / SEA KORDA
– Shine / SÄRA – Standardize / STANDARTISEERI
– Sustain / SÄILITA
• 5S and other Building Blocks of Lean
• A model for implementation
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5S and Other Building Blocks of Lean
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Agenda • Introduction to 5S
– Sort / SORTEERI
– Set-in-order / SEA KORDA
– Shine / SÄRA – Standardize / STANDARTISEERI
– Sustain / SÄILITA
• 5S and other Building Blocks of Lean
• A model for implementation
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1. Define the Target Area • Use masking tape,
existing boundaries (walls, floors, etc.), chalk line, etc. to etc. mark the official boundaries of the target area
• Make sure the target area is sized appropriately for the event
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0. VASTUTUSALAD
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2. Draw a Spaghetti Diagram
• Have a (scaled) drawing of the target area
• Draw the typical “flow” of people, materials and information
• This identifies motion and transportation waste
• May use to help re- layout area
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MATERJALID
TÖÖTAJAD
INFO
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3. Audit and Score • Use an audit checklist to set
a baseline score
• Train the auditors
• Understand that the first score typically is not high at the baseline
• Numerical (vs. yes/no)
• Use of 5S “Levels”
• Standardize and customize your audit checklists
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4. Before Photos A picture is worth one- thousand
words
• Issues “pop” off the picture
• Take overall area shots
• Safety issues
• Anything that would be a good Before and After photo
• Mark the locations on an area map or Photo Log to be able to take after photos
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5. Communication Board • Use to keep everyone
informed
• Audit Scores
• Before and After photos
• Spaghetti diagram
• 5S News
• Have short meetings by the board
• Put it in a convenient location
• Keep it current!
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Agenda
•5S workplace organization –introduction
–pilot overview and before / after
–conclusions / further steps
•Facility layout
•Summary
15 May 2012
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Agenda
•5S workplace organization –introduction
–pilot overview and before / after
–conclusions / further steps
•Facility layout
•Summary
15 May 2012
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1. SORTEERI
ALUSTATUD
LÕPETATUD
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2. SEA KORDA
ALUSTATUD
LÕPETATUD
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3. SÄRA
ALUSTATUD
LÕPETATUD
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4. STANDARTISEERI
ALUSTATUD
LÕPETATUD
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5. SÄILITA
ALUSTATUD
LÕPETATUD
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5S KAS PARIM VOOG?
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5S KES JÄRGMINE?
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DIMA 1.1
DIMA 1.2
SERGEI
TIIT 3.1
BORIS 4.1
5S TSOONID JA VASTUTAJAD
2.1
2.2
2.3
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Made with Office Timeline 2010 www.officetimeline.com 5S EDASISED SAMMUD
' 12 veebr 2012
märts apr mai ' 12
Today
5S TOOTMISES JUURUTATUD VÄRVIMINE: •OEE EFEKTIIVSUSE MÕÕTMINE •SMED SEADISTAMISAJADE VÄHENDAMINE
11.5.12
1S ISESEISVALT TEHTUD KOGU TOOTMISE ULATUSES
1.4.12
1S DIMA 20.2.12 20.3.12
1S BORIS 20.2.12 20.3.12
1S SERGEI 15.3.12 30.3.12
1S TIIT 15.3.12 30.3.12
4S, 5S DIMA 20.3.12 30.4.12
VÄRV OEE MÕÕTMINE PILOOT 2.4.12 13.4.12
5S JUURUTAMINE KOGU TOOTMINE 2.4.12 11.5.12
VÄRV SMED SEADISTAMISAJADE VÄHENDAMINE 13.4.12 4.5.12
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5S and Other Building Blocks of Lean
OEE – seadmete efektiivne
kasutus
SMED – kiired üleminekud
Kanban – voogu juhtimine
MÕÕDAME PROTSESSI !
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Agenda
•5S workplace organization –introduction
–pilot overview and before / after
–conclusions / further steps
•Facility layout
•Summary
15 May 2012
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Agenda
•5S workplace organization
•Facility layout – sisejuhatus / introduction – algandmed / basic data
– võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
15 May 2012
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sissejuhatus • tsükli aeg / cycle time
• vajalik kapasiteet / desired capacity
• takti aeg / tact time
• takti kestus / tact duration
• protsessi partii / batch size
• tsükli aeg tk. kohta / cycle time per pc
• balanseerimine / balancing
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Agenda
•5S workplace organization
•Facility layout – sissejuhatus / introduction
– algandmed / basic data – võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
15 May 2012
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algandmed – mahud
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algandmed – mahtude kasv
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algandmed – olevik vs tulevik
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algandmed – 2012 takt * 7 h/day
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algandmed – flush door
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Agenda
•5S workplace organization
•Facility layout – sisejuhatus / introduction
– algandmed / basic data
– võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
15 May 2012
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võimsuste arvestus – flush door
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võimsuste arvestus – flush door
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võimsuste arvestus – flush door
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võimsuste arvestus – flush door
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võimsuste arvestus – flush door
takt
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Agenda
•5S workplace organization
•Facility layout – sisejuhatus / introduction
– algandmed / basic data
– võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
15 May 2012
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•5S workplace organization
•Facility layout – sisejuhatus / introduction
– algandmed / basic data
– võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
Agenda
15 May 2012
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pudelikaelad
• Plekikeskus 1tk * 1,5 vahetust
• Painutuspink 2tk * 2,0 vahetust
• Liimimispress 1tk * 1,5 vahetust
• Enne värvimist pooltoodang
• Peale värvimist pooltoodang
• Värvimine 1tk * 3,0 vahetust
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•5S workplace organization
•Facility layout – sisejuhatus / introduction
– algandmed / basic data
– võimsuste arvestus / capacity calculations
– tsehhi plaan / facility layout
– pudelikaelad / bottle necks
– kokkuvõte / conclusions
•Summary
Agenda
15 May 2012
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kokkuvõte • Takti-põhine voogu määramine
• U-kujuga “liinide” kasutamine
• 1,5 jne ressurside hõivatus
• prognoositavate mahtude täpsus
• töömahukate prossesside analüüs
• otsustada: lisa masin või 3 vahetust?
• seadmete reaalne effektiivus OEE%?
• seadmete seadistamise ajad – SMED ?
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Agenda • 5S
•Facility layout • Summary
15 May 2012
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Agenda • 5S
• Facility layout
•Summary
15 May 2012
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BRIAN SAINSBURY / ROMAN ZAHHAROV 08/02/12
- FACILITY LAYOUT DESIGN - 5S WORKPLACE ORGANISATION