Through the Eyes of an Expert       Through the Eyes of an Expert                     Self-Balancing:                     ...
PARTNERS BY DESIGNAgenda                                                                                       2  „   The ...
PARTNERS BY DESIGNConventional Continuous Flow                                                                   3 • Level...
PARTNERS BY DESIGNPercent Loading Chart                                                                                   ...
PARTNERS BY DESIGNLevel Loaded                                                                                   5        ...
PARTNERS BY DESIGNStandard Work Sequence                                                                              6   ...
PARTNERS BY DESIGNConventional Continuous Flow                                                              7   What about...
PARTNERS BY DESIGNWhat Really Happens                                                                          8  „ Artifi...
PARTNERS BY DESIGNConventional Continuous Flow                                                              9             ...
PARTNERS BY DESIGNConventional Continuous Flow                                                             10             ...
PARTNERS BY DESIGNRipe for Improvement                                                                     11   What if yo...
PARTNERS BY DESIGNTrue Continuous Flow?                                                                        12 „   Get ...
PARTNERS BY DESIGNOriginal Arrangement “Un-Level Loaded”                                                        13        ...
PARTNERS BY DESIGNSelf-Balancing: True Continuous Flow                                                      14            ...
PARTNERS BY DESIGNSelf-Balancing Results: Micro-Optic Assembly Line                                                      1...
PARTNERS BY DESIGNSelf-Balancing Rules                                                                        16„ Keep bui...
PARTNERS BY DESIGNSelf-Balancing Work Sequence                                                                     17     ...
PARTNERS BY DESIGNLive Demo                                                                                18            3...
PARTNERS BY DESIGNSelf-Balancing Features and Benefits                                                          19  „   El...
PARTNERS BY DESIGNRequirements of Self-Balancing                                                              20„ Progress...
PARTNERS BY DESIGNContiguous Cross-Training Matrix                                                            21          ...
PARTNERS BY DESIGNChallenges to Self-Balancing                                                                  22 „   Get...
PARTNERS BY DESIGNWhere Does Self-Balancing Apply?                                                               23 „   An...
PARTNERS BY DESIGNHonoring Workers, Honoring Results                                                          24 „ 30-100%...
PARTNERS BY DESIGNAre We Self-Balancing Yet?                                                                25            ...
PARTNERS BY DESIGNClosing Slides                                                                                          ...
PARTNERS BY DESIGNClosing Slides                                                                                          ...
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Through the Eyes of An Expert: The Future of Manufacturing

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Gordon Ghirann, lead manufacturing specialist, joined Speck Design for the latest series installment of Through the Eyes of an Expert to discuss the manufacturing process, self-balancing, as part of his new book, "Self-Balancing Processes: True Continuous Flow".

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Transcript of "Through the Eyes of An Expert: The Future of Manufacturing"

  1. 1. Through the Eyes of an Expert Through the Eyes of an Expert Self-Balancing: Self-Balancing: True continuous flow True continuous flow Gordon L. Ghirann, Lean Specialist Gordon L. Ghirann, Lean Manufacturing SpecialistPARTNERS BY DESIGN
  2. 2. PARTNERS BY DESIGNAgenda 2 „ The last 100 years „ Myths „ Self-Balancing „ Video examples „ Live demonstration „ Challenges to Self-Balancing „ Q&A Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  3. 3. PARTNERS BY DESIGNConventional Continuous Flow 3 • Level Loading ‟ Dividing up the work evenly among each Operator • Highlight waste at each station/Operator ‟ Focus on discrete processes • Everybody works to TAKT ‟ The line runs at a steady pace • WIP buffers ‟ Extra inventory between stations to account imbalances Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  4. 4. PARTNERS BY DESIGNPercent Loading Chart 4 100 90 T/T 80 70 OP 4 OP 60Time OP 7 50 2 OP 40 OP 9 30 OP 6 1 OP 20 OP 8 3 OP 10 5 0 1 2 3 4 5 6 7 8 9 Rough Finish Deburr Mill Deburr Drill Grind Wash Inspect Turn Turn Slots Holes Operations Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  5. 5. PARTNERS BY DESIGNLevel Loaded 5 100 90 T/T OP 8 80 OP 6 OP 5 70 OP 3 OP 9 60 50 Time 40 OP 2 30 OP 4 OP 7 20 10 OP 1 0 A B C 1. Rough Turn 4. Mill Slots 7. Grind 2. Finish Turn 6. Drill Holes 9. Inspect 3. Deburr 5. Deburr 8. Wash Operators Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  6. 6. PARTNERS BY DESIGNStandard Work Sequence 6 Machine Sequence The order in which an Operator performs manual operations. entrance Work sequence exit Operator A 1 1 2 9 Operator C 5 8 2 2 3 3 1 7 Operator B 4 1 2 6 4 5 Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  7. 7. PARTNERS BY DESIGNConventional Continuous Flow 7 What about the experience of the Line Worker? Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  8. 8. PARTNERS BY DESIGNWhat Really Happens 8 „ Artificially balanced „ Can’t handle variations in yield, cycle time, and demand (without adding waste) „ Designed-in waiting „ In-Process queues (WIP) „ Silo mentality (factory condo) „ Difficult to adjust output, inflexible „ Absenteeism can shut down line „ “Slowest” Operator/station (Herbie) sets the pace! „ Repetitive, dehumanizing work „ Social cost Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  9. 9. PARTNERS BY DESIGNConventional Continuous Flow 9 Myth #1: “Assembly lines work to TAKT” Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  10. 10. PARTNERS BY DESIGNConventional Continuous Flow 10 Myth #2: “Level Loading can lead to Continuous Flow” Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  11. 11. PARTNERS BY DESIGNRipe for Improvement 11 What if your primary goal was to achieve continuous flow? Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  12. 12. PARTNERS BY DESIGNTrue Continuous Flow? 12 „ Get rid of any In-Process queues „ Get rid of any waiting „ End of the line would trigger the pull „ Abandon trying to level load „ Get rid of the chairs so people can move „ Never set the part down Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  13. 13. PARTNERS BY DESIGNOriginal Arrangement “Un-Level Loaded” 13 100 90 T/T 80 70 OP 4 OP 60 Time OP 7 50 2 OP 40 OP 9 30 OP 6 1 OP 20 OP 8 3 OP 10 5 0 A B C D E F G H I Rough Finish Deburr Mill Deburr Drill Grind Wash Inspect Turn Turn Slots Holes Operations Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  14. 14. PARTNERS BY DESIGNSelf-Balancing: True Continuous Flow 14 Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  15. 15. PARTNERS BY DESIGNSelf-Balancing Results: Micro-Optic Assembly Line 15 60% gain Batch & Level Self- Overall %PER CELL Queue Load Balance ImprovedProductivity (unit/hr-person) 0.30 0.35 0.56 87%WIP inventory 810 80 24 97%Lead Time (days) 10 3 0.7 93%Cumulative Yield* 64% 65% 83% 19%Space (sq. ft) 750 550 550 27%Walking Distance (ft) 525 270 250 52%Part Travel Distance (ft) 493 152 140 72%*Simultaneous yield improvement projects implemented, highly sensitive to product mix Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  16. 16. PARTNERS BY DESIGNSelf-Balancing Rules 16„ Keep building (progressively) until someone pulls from you„ When the downstream person pulls from you, walk upstream until you run into someone, then pull from them„ If you catch up to someone, wait„ Don’t “leapfrog”, everyone stays in their position„ Communicate, Communicate, Communicate! Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  17. 17. PARTNERS BY DESIGNSelf-Balancing Work Sequence 17 Work content may vary slightly each cycle Operators work in positions exit entrance (not a “rabbit chase”) 1 9 2 Operator A Operator C 8 Position 1 Position 3 3 7 4 Operator B 6 Position 2 5 Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  18. 18. PARTNERS BY DESIGNLive Demo 18 3 VOLUNTEERS Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  19. 19. PARTNERS BY DESIGNSelf-Balancing Features and Benefits 19 „ Eliminates waiting (optimal division of work) „ Simple, eloquent, flexible „ Operator paced (unleash your all-stars) „ No WIP Buffers „ Operators, not parts, accumulate at problems „ Silo’s disappear „ Increased yield „ Reduced Secondary Labor support „ No more line balancing! „ A bias towards flow Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  20. 20. PARTNERS BY DESIGNRequirements of Self-Balancing 20„ Progressive Assembly/Processing horizontal parts and tools presentation„ # of stations > # of Operators„ Standard Work (the real thing!)„ Infinite hand-off points„ Contiguous x-training„ Standing/walking line (for maximum productivity ergonomics) Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  21. 21. PARTNERS BY DESIGNContiguous Cross-Training Matrix 21 Task 1 Task 2 Task 3 Task 4 Task 5Operator X X AOperator X X X BOperator X X C Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  22. 22. PARTNERS BY DESIGNChallenges to Self-Balancing 22 „ Getting rid of the chairs „ Fatigue „ Low TAKT, “clumsy” hand-offs „ Debugging „ Highlighting waste at a station Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  23. 23. PARTNERS BY DESIGNWhere Does Self-Balancing Apply? 23 „ Anywhere there are queues „ Anywhere there is a standard sequence „ Mixed Model „ Anywhere there are balance issues ‟ Business Processes ‟ Product Development ‟ Transactional Processes Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  24. 24. PARTNERS BY DESIGNHonoring Workers, Honoring Results 24 „ 30-100% Productivity Gains „ WIP Reduced 50% „ Lead Times Reduced 50% „ Improved Yields „ Improved Employee Satisfaction ‟ Dynamic, diverse work ‟ Easier Cross-Training ‟ Improved communication ‟ Real teams „ Reduced Social Cost Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  25. 25. PARTNERS BY DESIGNAre We Self-Balancing Yet? 25 Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  26. 26. PARTNERS BY DESIGNClosing Slides 26 About Gordon L. Ghirann: Gordon L. Ghirann is a lean manufacturing specialist at JDSU, a leading provider of optical products and test and measurement solutions for the communications industry. It was while working as a manufacturing engineer at Kilovac, that Ghirann first discovered the self-balancing process. Ghirann describes self-balancing as a process that encourages communication and collaboration among workers within a team-based environment, thereby eliminating the need for self-pacing. By successfully implementing the self balancing method at numerous companies and industries around the world, Ghirann has helped reduce COGs, alleviate the human-cost of manufacturing, and improve quality control. He received his B.S. in Mechanical Engineering from Cal Poly, San Luis Obispo, and is a regular top presenter at the annual Association of Manufacturing Excellence (AME) conference. This fall, Ghirann is releasing his book, Self-Balancing Processes: True Lean Continuous Flow, the culmination of 13 years of manufacturing practice and research. For information on his book visit: http://www.crcpress.com/product/isbn/9781439819654;jsessionid=qoZi8qivnpODhHhsyjg1Lw Ghirann offers workshops in which participants learn how to set up a self-balancing line, from simple to complex manufacturing environments. He is also available for consultation to assess how your company could benefit from the self-balancing process. Contact information: (707) 799-0942 selfbalancing@gmail.com Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
  27. 27. PARTNERS BY DESIGNClosing Slides 27 About Speck Design: For 15 years, Silicon Valley companies have turned to Speck Design to develop breakthrough products in medical, industrial, consumer and data communications. Our growth comes from repeat business and referrals, and our teams consist of trusted experts whom our clients rely on project after project, year after year. Services we offer include research, industrial design, engineering, testing and transfer to manufacturing. Known for reliability, flawless execution by fearless designers, and solutions that help grow our customers’ sales, Speck Design delivers a “partners by design” relationship in every product design project. To learn more, go to www.speckdesign.com Contact information: (650) 462-9080 info@speckdesign.com 3221 Porter Drive, Palo Alto, CA 94304 Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann ©2011 Speck Design
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