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FlexQube Lean Production Webinar Dec 22 - 2016
This document discusses the evolution and principles of lean production. It provides a brief history starting with Frederick Taylor's scientific management principles in the 1890s through Toyota's just-in-time production system developed in the 1940s-1980s. The core aspects of lean production are outlined as focusing on customer value, respecting people, eliminating waste, maintaining flow and pulling work through the system. Various types of waste are defined and the reader is asked to identify examples in their plant. Continuous improvement and going to see processes firsthand are emphasized. Potential applications of lean thinking to material handling and factory logistics are explored through examples.
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FlexQube Lean Production Webinar Dec 22 - 2016
- 1. LEAN PRODUCTION 2016.12.22 Per Augustsson CTOFlexQube Group LIVE WEBINAR © FlexQube AB 2011-2016. All rights reserved.
- 2. Frederick Taylor Scientific management Timestudies 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 LEANPRODUCTION 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 ISMORE 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 • Alwayswork 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
- 6. FLEXQUBE® FLEXBEAM™ FLEXTUBE™ FLEXPLATE™ THE FLEXQUBE® BUILDING BLOCKS Thecore in the FlexQube® concept includes four different building blocks. All equipped with the famous pattern that ensures that all building blocks can be combined with each other into endless number of solutions.
- 7. CHALLENGES FLEXQUBE OFFERSOLUTIONS BUILDING BLOCKS DESIGN 4 ALL DESIGN ON DEMAND WIDE CUSTOMER OFFER INCREASED COMPLEXITY ERGONOMIC CHALLENGES INCREASED SPACE FOR INTRA- LOGISTICS YOU DESIGN! FLEXQUBE DESIGN!
- 8. DESIGN ON YOUROWN – PERFECT KAIZEN EVENT
- 9. DESIGN4ALLTM Create onyour own with www.onshape.com
- 10. GATHER YOUR TEAMAND GET CREATIVE! PROJECT BUDGET LOAD CAPACITY INTEGRATION WITH OTHER EQUIPMENT FACTORY LAYOUT NUMBER OF CARTS ERGONOMIC REQUIREMENTS HOW TO MOVE CARTS DESIGNONDEMAND™ YOUPROVIDETHEINPUT–WEDOTHEDESIGN!
- 11. 20101960 LIFECYCLES $ $ $$ INCREASING NUMBER OF PRODUCTS
- 12. THE PAST PRESENTFUTURE? 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
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- 14. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • WAITING DUE TO QUALITY PROBLEMS • WAITING FOR A BREAKDOWN TO BE RESOLVED • WAITING FOR A PREVIOUS PROCESS STEP • WAITING FOR THE FORKLIFT TO DELIVER PARTS
- 15. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • SEARCHING FOR TOOLS AND EQUIPMENT • WALKING ACROSS WORKSPACE TO RETRIEVE PARTS • TURNING AND MOVING PRODUCT DURING ASSEMBLY • REORIENT COMPONENT WHEN TAKEN FROM CART • REACHING EXESSIVE DISTANCES WHEN TAKING COMPONENTS AND TOOLS
- 16. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • THE TRANSPORT OF PRODUCT FROM ONE FUNCTIONAL AREA TO ANOTHER • THE USE OF MATERIAL HANDLING DEVICE TO MOVE MATERIAL FROM ONE MACHINE TO ANOTHER • THE TRANSPORTATION OF CHEAPER COMPONENTS FROM ONE COUNTRY TO ANOTHER
- 17. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • PARTS ASSEMBLED WIH INCORRECT ORIENTATION. • MISSING SCREWS AND OTHER FIXINGS • INCORRECT COMPONENTS USED IN ASSEMBLY • PARTS DAMAGED DURING TRANSPORTATION • FAULTY PRODUCTS THAT ENDS UP AT CUSTOMER
- 18. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • COILS OF SHEET METAL WAITING TO BE PROCESSED • BUFFER OF BODY IN WHITES BEFORE ASSEMBLY • FINAL ASSEMBLED CARS ON THE YARD
- 19. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • WORST TYPE OF WASTE! • PRODUCING PARTS BEFORE THEY ARE NEEDED • PRODUCE A LARGE BATCH IN ORDER TO REDUCE SET UP TIME • PRODUCE PARTS IN ORDER TO HAVE HIGH UTILISATION OF MACHINES AND PEOPLE
- 20. WAITING MOTION TRANSPORT DEFECTS INVENTORY OVER PRODUCTION OVER PROCESSING WHAT WASTE CANYOU FIND IN YOUR PLANT? • PAINTING AREAS THAT WILL NEVER BE SEEN OR BE AFFECTED BY CORROSION • OVER POLISHING AN AREA THAT DOES NOT REQUIRE IT • TOLERANCES THAT ARE TO TIGHT
- 21. I WISH THE SUPPLIERCOULD 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 CD 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
- 23. MOTHER CART DAUGTHER CARTS SHELF CART BOX WITH KIT FOR ASSEMBLER CRANEASSEMBLY SEAT ASSEMBLY FLEXQUBE® INSPIRATION FROM THE FACTORY FLOOR
- 24. FLEXQUBE® INSPIRATION FROMTHE 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 WEHAVE? 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
- 26. FLEXQUBE® INSPIRATION FROMTHE FACTORY FLOOR
- 27. WHAT DO WEHAVE? 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
- 28. FLEXQUBE® INSPIRATION FROMTHE FIELD
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- 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
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- 32. 32 FlexQube extensive IndustryKnowledge INDUSTRY TRENDS INDUSTRY 4.0 FORKLIFT FREE LEAN PRODUCTION INTEGRATION TRADE SHOWS DIFFERENT CUSTOMERS WEBINARS CTO LETTERS PROJECT MANAGEMENT
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