2. Frederick Taylor
Scientific management
Time studies
Works standards
Frank Gilbreth
Process charting
Non value elements
Henry Ford
Assembly lines
Mass production
Eiji Toyoda
Toyota Production System
Just In Time
Stockless production
2016
http://www.strategosinc.com/just_in_time.htm
1890
1900
1910
1947
Western companies
shows interest
1980
HOW LEAN PRODUCTION HAS EVOLVED
Industry 4.0
Internet of
things
3. WHAT IS LEAN PRODUCTION ABOUT
1. Focus on effectively delivering value to
your Customer
2. Respect and engage the people
3. Improve the Value Stream by eliminating
all types of waste
4. Maintain Flow
5. Pull Through the System
6. Strive for Perfection
4. WAITING
MOTION
TRANSPORT
DEFECTS
INVENTORY
OVER
PRODUCTION
OVER
PROCESSING
PRODUCTION THAT IS MORE THAN NEEDED, OR BEFORE IT IS NEEDED
MOVEMENT OF PEOPLE AND EQUIPMENT
EFFORTS CAUSED BY REWORK OND SCRAP
MOVEMENT OF PARTS AND PRODUCTS
PEOPLE AND PARTS WAITING FOR NEXT STEP IN PROCESS
PARTS WAITING TO BE PROCESSED
MORE WORK OR HIGHER QUALITY THAN IS REQUIRED FROM CUSTOMER
WHAT WASTE CAN YOU FIND IN YOUR PLANT?
5. KAIZEN (改善)
Improvement
• Always work to fine tune your process and
procedures.
• Everything, regardless of how good it is, can be
made better.
• Small continuous improvements add up to big
changes.
• Without constant improvement, processes will
naturally degrade to a lower level of quality and
efficiency.
GEMBA (現場)
The real place
• Going to see the actual process
• Understand the work
• Ask questions
• Try, fail and learn
7. CHALLENGES FLEXQUBE OFFER SOLUTIONS
BUILDING BLOCKS DESIGN 4 ALL
DESIGN ON DEMAND
WIDE CUSTOMER OFFER
INCREASED COMPLEXITY
ERGONOMIC CHALLENGES
INCREASED SPACE FOR
INTRA- LOGISTICS
YOU DESIGN!
FLEXQUBE DESIGN!
10. GATHER YOUR TEAM AND GET CREATIVE!
PROJECT
BUDGET
LOAD
CAPACITY
INTEGRATION WITH
OTHER EQUIPMENT FACTORY
LAYOUT
NUMBER OF
CARTS
ERGONOMIC
REQUIREMENTS
HOW TO MOVE
CARTS
DESIGNONDEMAND™
YOUPROVIDETHEINPUT–WEDOTHEDESIGN!
12. THE PAST PRESENT FUTURE?
MATERIAL HANDLING AREA MANUFACTURING AREA
75% OFONITEMSPRODUCTIONCOSTISRELATEDTOMATERIALHANDLING
55% OFFACTORYSPACEISUSEDFORMATERIALHANDLING
http://clearpath.ottomotors.com/industry-4-0-ebook/
SELF-DRIVING VEHICLES FOR INDUSTRY
Innovation in an Interconnected World
Industry 4.0 and the power and potential of self-driving vehicles
MOREAREAUSED FOR LOGISTICS
21. I WISH THE
SUPPLIER COULD
SEND WITHOUT
THIS PACKAGING!
I WISH THE WAREHOUSE
COULD DELIVER THE
PALLETS IN ERGONOMIC
PICKING HEIGHT!
I WISH THE KITTING GUYS
PRESENTED THE PARTS
WITH CORRECT
ORIENTATION!
I WISH I DIDN’T HAVE TO
LIFT THE PRE ASSEMBLY
WITH CRANE TO ATTACH IT!
22. A B C D E
F G H I J
WHAT DO WE HAVE?
MATERIAL FACADE WITH PALLETS
WHO IS THE CUSTOMER?
THE ASSEMBLERS PICKING MATERIAL FROM THE PALLETS
WHAT DO WE WANT TO DO?
REDUCE THE WASTE OF MOTION RELATED TO ASSEMBLER WALKING
HOW CAN WE DO IT?
REDUCE THE WASTE OF MOTION RELATED TO THE PALLET SUPPLY
MOTION
INVENTORY
DEFECTS
1. IMPLEMENT MOTHER AND DAUGHTER TRAIN
2. USE DAUGHTER CART AS KIT CARTS
3. PREPARE PARTS FOR ONE ASSEMBLER ON CART
4. PLACE KIT CART CLOSE TO OPERATORS
5. ASSEMBLER PICKS MATERIAL FROM KIT CART
24. FLEXQUBE® INSPIRATION FROM THE FACTORY FLOOR
DUMP TRUCK
ASSEMBLY
FRAME WELDING FOR
WHEEL LOADER
FRIDGE ASSEMBLY
TRUCK EXHAUST SYSTEM
MANUFCATURING
INCUBATOR
ASSEMBLY
25. 3
2
1
5
4
WHAT DO WE HAVE?
SUPPLY OF PALLETS WITH FORKLIFT TO KITTING AREA
WHO IS THE CUSTOMER?
THE OPERATORS PICKING MATERIAL FROM THE PALLETS
WHAT DO WE WANT TO DO?
REDUCE THE WASTE OF MOTION RELATED TO THE PALLET SUPPLY
HOW CAN WE DO IT?
REDUCE THE WASTE OF MOTION RELATED TO THE PALLET SUPPLY
MOTION
4
5
2
3
1
1. IMPLEMENT TONGUE AND HITCH TRAIN
2. USE CARTS AS LOAD CARRIER FOR THE PALLETS
3. DEFINE ROUTE OF SUPPLY
4. DISCONNECT CART TO SUPPLY NEW PALLET
5. EMPTY PALLET GOES WITH THE SAME TRAIN
27. WHAT DO WE HAVE?
STORAGE OF STAMPED PARTS IN HIGH RACK STORAGE
WHO IS THE CUSTOMER?
THE OPERATORS WORKING AT THE WELDING WORK CELLS
WHAT DO WE WANT TO DO?
REDUCE THE WASTE OF MOTION AND INVENTORY IN THE WAREHOUSE
HOW CAN WE DO IT?
REDUCE THE WASTE OF INVENTORY WITH KANBAN CONTROL
PRODUCTION OF
LARGE BATCHES
ACCORING TO
SCHEDULE
MOTION
INVENTORY
OVER PROD.
PRODUCTION OF
SMALL BATCHES
ACCORDING TO
CART SIGNALBUFFER LANES
CART TRIGGERS
PREPARATION OF
STAMP TOOL FOR
PART D
STORAGE IN
RACKS
STORAGE IN
RACKS
1. PLACE PARTS ON CARTS INSTEAD OF PALLETS
2. USE CARTS AS KANBAN CARD
3. TOTAL NUMBER OF CARTS LIMITS INVENTORY
4. YOU ONLY PRODUCE AS LONG THERE IS EMPTY CARTS
5. EMPTY CART TRIGGERS NEXT STAMPING ACTION
30. SELF DRIVING VEHICLES
http://europe.autonews.com/article/20160321/ANE/160329996/bmw-seeks-to-cut-costs-with-
autonomous-vehicles-on-the-factory-floor
• With assembly lines already sharply honed, moving
around parts is one of the last remaining areas
open for improving productivity. The process has
also become increasingly complex as factories
often produce multiple models on a single line and
more and more customization options are being
offered to woo modern consumers.
• Expects will help cut costs by 5 percent per car
annually.
• the vehicles autonomously find the desired parts
container, slide under it and transport it to the
packing area.
• The system saves money over the current manual
process with shorter response times and improved
inventory flows, Oliver Zipse, BMW's production
chief
MOTION
INVENTORY
32. 32
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