FMC modular flow guidelines 08-03-13

© 2009 Duggan Associates. All Rights Reserved. 1
FMC MODULAR FLOW
PRINCIPLES
Duggan Associates
www.dugganinc.com
08/03/2013

• 20 Principles of Flow
• Foundations
• Safety
• TPM
• 5S
• Tooling Presentation
• Material Presentation
• Flow through High Bay
FMC MODULAR FLOW PRINCIPLES

• 20 Principles of Flow
FMC MODULAR FLOW PRINCIPLES

FMC Modular Flow Principles
Within each Workstation:
•No Safety violations
•No forklifts, no cranes, no hoists
•No trash containers in production areas
•No pits, no platforms
•No process flow reversals
•Mistake-proofing;
•Color coded go, no-go gages
•Everything must be less than 1.5 meters (5 feet) in height
•Visual Boards to show if station is on time
•Product and Operators do not leave the cell or line
•Daily equipment checks and TPM carried out routinely, no unplanned
equipment downtime that reduces available working time
•Quality issues are identified and addressed.

FMC Modular Flow Principles
Across the Flow of High Bay:
11.One-Piece Tree Flow
12.Value Stream Map exists that show the new designed flow
13.Inspection processes upstream in modules
14.Modules built in parallel
15.Systems and Standard Work in place to prevent part shortages
16.Cross training is achieved; everyone can do everything, based upon
and know if they are on-time
17.Pitch used to pace the process
18.Visual Boards showing performance metrics
19.Plans for when flow breaks down
20.Management teaching and guiding on flow principles

Foundations for Modular Flow
• Safety
• Non-Negotiable
• Health, Safety, Environment
• TPM
• 5S

Non-Negotiable
Health, Safety, Environment

Non-negotiable Safety Reqs.
•Fire extinguishers will be clearly marked by class (A, B, C) and
will meet NFPA standards. Extinguishers with gross weight not
exceeding 40 pounds should be installed so that the top of the
extinguisher is no more than five feet above the floor.
•Electrical breakouts will be clearly marked and have a 36” inch
clearance and be free of obstruction per OSHA guidelines
•Egress walkways will be free of obstruction and parking areas
for equipment and tooling and will be clearly marked.
•All flammable chemical cabinets will be grounded per 29 CFR
1910.106 and clearly marked with picture of cabinet contents
as well as FIFO system to avoid use of expired chemicals.

Non-Negotiable
• Fire extinguishers will be clearly marked by class (A, B, C)
and will meet NFPA standards. Extinguishers with gross
weight not exceeding 40 pounds should be installed so that
the top of the extinguisher is no more than five feet above
the floor.

HAZMAT Control/ Chemical
HandlingVisual Coding of
expiration
Type/MSDS info and
expiration are clearly marked

Chemical Cabinet 5S
• Chemical cabinet
should have picture of
contents and display
proper and in-proper
condition

TPM

PPE & TPM Requirements listed at each
Station
13
• PPE and TPM
requirements
are listed at
every
workstation

Visual Gauge markings
14
Gauge Highlighting:
Red - failure mode
Yellow – warning/execute control plan
Green - normal

VISUAL STANDARD
ATTRIBUTES OF VISUAL
Identify Pipes at Key Locations Only
Highlight Processes, not Facilities.
Pipe Labels are “Snap-on” Collars:
Supplier Grainger item # 6GT35
Color Code Based upon ASME A13.1 –
2007 US Piping Identification Standards
15
Pipe Labeling
Material
Backgrou
nd Color
Legend
Letter
Color
Background
Color and
Letter Sample
Fire quenching (water, foam, CO2,
etc)
Red White LEGEND
Toxic and corrosive Black LEGEND
Flammable Yellow Black LEGEND
Combustible Brown White LEGEND
Water (potable, boiler feed, cooling,
etc)
Green White
LEGEND
Compressed air Blue White LEGEND
Defined by site (for other materials
not listed)
Purple White
LEGEND
not listed)
White Black
LEGEND
not listed)
Gray White
LEGEND
not listed)
Black White
LEGEND
ND
LEGENDLEGEND
LEGEND
Label at line of sight

5S FOR FLOW

BLUE Work in Process
YELLOW Main Aisles, General Areas, Cart Parking Areas
YELLOW / BLACK Machine Guarding
RED Electrical Shutoffs/ Fire Protection/ Defective Material
GREEN Final WorkStation
ORANGE Moving Crane Parts, Compressed Gas Racks
Visual Factory Guidelines

VISUAL standard
Solid Lines or Corners for
Floor Markings
18
Floor Marking
EH&S, Non/Hazardous Waste,
Non-conforming material
Incoming/Outgoing Product
(Raw or Finished Goods)
WIP in Work Cell
Main Aisle Borders
4” width
2” width
2” width
2” width
2” width
Cart Parking Location
Standard Corners
Floor Tape Specification: High-
Strength, Double-Coated Tape,
Removable Pressure Sensitive
Rubber-Based Adhesive. Source:
WWW.Mightyline Store.com
Note: Standard colors for manufacturing areas

Material Presentation for Modular
Flow

• Material Presentation Guidelines
• Creform Kit Carts
• Heavy Part Delivery Carts
• Extra Large Parts
• Standard Work for Developing Material
Presentation
Material Presentation for Modular Flow

Presentation

Guidelines
• Forklifts and cranes restrict flow. Eliminate the use of forklifts and cranes for
material delivery to the cell and material handling in the cell as much as
possible.
• Forklifts should never enter the station. If forklift delivery is required, it should
be at the front of the station
• Searching for a part should never happen
• No unpacking/opening boxes/searching through containers should happen at
station
• No carts over 5 ft, as it will block operator view

Guidelines
• Material Presentation is designed in advance not arrange while working
• Parts should be presented to technicians similar to a surgeon in an operating room
• Material availability should be so ‘transparent’ that a visitor should be able to tell if all of the
parts needed are present
• We should be able to easily tell if we have a clean start
• Each part should have a dedicated and easily identifiable location and usage
• Maximize use of material carts (one person can move without any material handling devices)
where safety is not compromised
• Material should be delivered at preset time (pitch). The target time should be half of a shift
with a maximum of one shift.

Guidelines
Are all of the parts available for a clean start?

Presentation

Material Presentation Carts
In order to eliminate the use of cranes and
pallets and to provide point of use parts to
operator with no unpacking or waste generation
as much as possible parts will be presented to
the operators on carts.
Two type of carts: Creform cart and Heavy Part
Delivery cart
•*Under XX lbs use Creform kit carts
•*Over XX lbs use heavy part delivery cart (need
name for this cart)
*Need to finalize sizes globally

Creform Kit Carts
• Modular carts made with Creform
• Standard sizes (target 3)
Example:
•Small = 2 x 2 x 3’
•Medium = 2 x 4 x 4’
•Large = 3 x 6 x 5’
*Need to finalize sizes globally

Creform Kit Carts
Many options for creform cart configurations

Creform Kit Carts
• Parts shadowed for material
presentation
• Designated location for each part
• Missing parts are easily identifiable
Reference sites:
• http://plasticeng.com/
• http://www.youtube.com/watch?v=r8A7jPR72o4&feature=

Creform Kit Carts
Small Parts
Standard method needed for small parts
commonly used
• Nuts/Washers => Size specific
rods??
• Shafts => PVC tubes?
• Bolts => Containers ??
Right quantity must be easily visible

Presentation

Heavy Part Delivery Cart
Heavy parts (>XXlbs or >X’xX’)
• Universal base
• Heavy duty/stable
• Single person can move it
• Multiconfigurable for different
parts/projects

After some design work heavy duty universal
base accepts custom tops
Update with liftup red top
and label 3 parts

After some design work heavy duty universal
base accepts custom tops
Configurable top
Universal base
Forklift Guides
Make pic on left
like picture on right

Real life example

Heavy Part Delivery Cart can be use for
parts like these.

Presentation

Extra Large Parts
Other methods to remove forklifts should be
utilized

AirFloat
• Movable air pallets
• Air Platform XL can move up
to 150,000 lbs
• U pallet can be used for
material presentation
• Cost effective XL platform
ranges from 15K to 30K
Air platform XL
U pallet platform
Air Bearing Skid
http://www.airfloat.com/equipment/air-platforms/

Presentation

Material Presentation Docs
• Complete PFEP, Kitting Form, and Station
Design (Pitch) Form
Sequence Part # Model Part Description
Usage
Location
Storage
Location
Order Frequency Supplier
Container
Type
Standard
Container
Qty.
Quanti
ty per
Tree
Weight
(kilograms)
X (in.) X Y (in.) Y Z(in.)
Shipment
Size
T/T
>P1000091950 DU100145239 EVDT ASSY, 5 1/8 X 2 1/16-15K, 183/4
TORUS IV 15K BTM X 18 3/4 H4 TOP,
PRODUCTION XT, HESS TUBULAR BELLS
1 93600(42457) 0.0 0.0 0.0 0.0 0.0
1 >>P1000108956 DU100144443 XT SECONDARY MODULE EVDT ASSY, 5
1/8 X 21/16-15K, 18 3/4 TORUS IV 15K
BTMX 183/4 H4 TOP, PRODUCTION XT,
HESS TUBULAR BELLS
1 50225(22782) 0.0 0.0 0.0 0.0 0.0
2 >>P1000108957 DU100144444 LOWER TREE FRAME SECONDARY
MODULE, 5-15K EVDT, PRODUCTION XT,
HESS TUBULAR BELLS
1 29496(13380) 0.0 0.0 0.0 0.0 0.0
3 >>P1000110098 DU100144013 FRAME ASSY, VERTICAL SUPPORT, PROD
SIDE, 5-15K EVDT, W/ ANODE
1 358(163) 10.8 273.1 56.2 1427.0 68.9
4 >>P1000088841 DU100116649 FRAME ASSY, VERTICAL SUPPORT, ANN
SIDE, 5-15K EVDT, W/ ANODES
1 628(285) 15.9 404.1 62.6 1589.0 101.5
5 >>P1000104320 DU100122560 ROV PANEL, ASSY, CIT ON PSDV, F/ 5-15K
EVDT
1 62(29) 15.5 393.7 16.8 426.5 20.7
6 >>P1000090022 DU100113731 GROUP OF PARTS, SET-OUT, F/
ACCUMULATOR SUB-ASSEMBLY F/ 15K
EVDT
1 581(264) 15.9 403.2 24.3 616.3 64.6
7 >>P1000072658 DU100086333 UPPER TREE FRAME WELDMENT, ROOF
STRUCTURE, F/ 5-15K EVDT
1 2190 (994) 138.5 3518.0 104.8 2661.0 30.6
Timing (zero
to full shift)
Part Number Part description Quantity
Material Handling Device
(Delivery to Station)
Size of Part Number- Special Tooling Needs-
Special Material
Handling Needs-
Safety
Concerns
Day 1/0HRS P1000108957 FSM 1 Crane (50 tons)/Slings N/A FSMhandling tool
P1000096309 U/S FLOWLOOP 1 Forklift/Pallet 49.77X 53.69X 16.50 Off set handling tool
P153000 NUTS 12 Kit cart 3.38X 3.19X 1.49
P1000048292 STUDS 12 Kit cart 2.1X 2.1X 7.63
73-062-169 GASKET 1 Kit cart 6.83X 6.83X 0.62
P1000108956 TSM 1 Crane (50 tons)/Slings N/A
6 HRS P1000107431 HVY HEAD SCREW 12 2.7X 2.34X 3.72
P137440-0000 WASHER 12 2.4X 2.39X 0.07 2.5
P153000 NUTS 24 3.38X 3.19X 1.49
P1000048638 STUDS 12 2.02X 11.5X 2.02
73-062-169 GASKET 1 Forklift/Pallet 6.83X 6.83X 0.62
12 HRS P1000080183 SPACER SPOOL BODY 1 Forklift/Pallet 0X 0X 0
P152164 GASKET 4 Forklift/Pallet 1.68X 1.68X 0.38
P1000100723 WELD NECK FLANGE 1 2.17X 8.57X 6.38
P1000072699 SPACER 1 3.38X 2.28X 2.28
P206197 PAD STUDS 4 NO-DWG
78-035-032 NUTS 8 NO-DWG
P153495 PAD STUDS 4 NO-DWG
P160931 ASV bucket 1 13.97X 18.37X 8.55
P136404-0000 PSV bucket 1 13.97X 18.37X 8.55
P1000104320 PSDV Panel 0 15.5x16.8x20.7
P1000104152 ROV PANEL, WELDMENT 1 15.5x15.8x20.7
P1000101407 PAD STUD 2 NO-DWG
P1000015761 WASHER 6 NO-DWG
P151280 ACTUATOR PROTECTOR PLATE 2 1.5x1.5x5.4
P1000085679 NUTS 2 NO-DWG
P111363-0000 WASHER 2 NO-DWG
P1000108511 D/S 2" Flowloop 1 61.34X 33.97X 72.17
73-062-152 GASKET 2 NO-DWG
P101228-0004 PAD STUD 8 NO-DWG
78-035-043 NUTS 24 NO-DWG
P153246 STUDS 8 NO-DWG
Pitch # 8
Time
Cum.
Time
NPT
Factor
NPT
Adjus
ted
Time
NPT
Adjus
ted
Cumu
l.
Time
Technician 1 Technician 2 QA Technician 4 Item #
Material Part
Number
Description Quantity Tooling Required
In station material
handling (crane, slings..)
Check for common mistakes (failures)
(visual inspection/hands on quality failures)
JSA form
4 >>P1000088841 LEFT SIDE SUPPORT 1 Combo wrench Crane
207 >>P1000093498 BOLTS 4 Sockets set Slings
225 >>P1000085680 NUTS 4 Hammer
231 >>P1000034346 WASHERS 8 Hex key set
229 >>P163166 WASHERS 16 Depth mic
46 >>P1000104465 ROV EXTENSION ROD 1 Off set handling tool
35 >>P1000009878 COUPLER KIT 1
40 >>P1000009857 SLEEVE KIT 1
47 >>P1000090277 ROV EXTENSION ROD 1
34 >>P1000009880 COUPLER KIT 1
39 >>P1000009855 SLEEVE KIT 1
Extension Rods Hex key set
Combo wrenchs
15 >>P1000113381 PROTECTION PLATE 1 Combo wrench Crane
208 >>P1000093499 BOLTS 4 Sockets set Slings
225 >>P1000085680 NUTS 4 Off set handling tool
231 >>P1000034346 FLAT WASHER 8 Milliohm Meter
229 >>P163166 STAR WASHERS 16
16 >>P1000113529 COUNTERWEIGHT 2 Combo wrench Crane
75 105
Install Sm. Valve Ext.
Rods. (qty5)
Install Sm. Valve
Ext. Rods. (qty4)
30 135 Install Protection Plate CP Check
Install Conterweight to
Project # Tubular Bells Station # 1 Day # 2 Pitch Time: 6hrs
60 90
Install Left Side
Support/ Install ROV
Extension Rod to PSV
Install ROV
Extension Rod to
ASV/ Install ASD
Funnel
Measure depth
PSV and ASV
30 30 JSA JSA

Create Creform Prototype
Work with one pitch at a time
1.Sort parts by weight/cart type
• Creform cart
• Small parts(fasteners, etc..)
• Parts under XX lbs
• Heavy parts – over xx lbs
• Extra Large parts
2.Collect all available parts
3.Where parts are not available obtain a 3-D drawing

Create Creform Prototype
4. Select tray size (from standard list) and cut
cardboard to selected size
If parts are available:
• Arrange parts on cardboard
• Trace parts onto cardboard
If parts are not available:
• Obtain an actual size drawing of the part
• Cut part out of drawing to make paper
template
Create several options were possible
*Note - Part layouts should follow installation
sequence and not cart optimization

Prototype Cart Reviews
• Conduct walk thorough
of tasks with prototype
cart options
• Determine best cart
layout with technicians
• Take pictures and
trace finished designs
• Document cart sizes in
the Kitting Form

Point of Use Tooling

Point of Use Tooling Hand Tools
• All hand tools will be shadowed and will be Point of Use
• Mounted on creform at workstation with wheels
• Only what is needed will be at each station `

Point of Use Tool Control
• Tools are clearly identified location and tool type with
picture make it easy for even a customer to know if
something is missing

POU TOOLING
IMPLEMENTATION
POU Tooling and fixture at employee’s reach.
NO TOOLBOXES

Creating tool shadow boards
52
http://plasticeng.com/

VISUAL STANDARD
POU (Point of Use) Tool Location
Tool Accountability
FOD Prevention
Clear Color Contrast Between Top
and Bottom. (See slide 6 plastic
engineering)
53
Tool Shadow Boarding

Tooling Presentation
Tool Accountability
Highlights Tool Status
Missing Tool Replaced With
Physical Item Describing Tool
Status
FOD Prevention
54
Note: Standard is to have tool control method in place

MODULAR FLOW

5 Station Design Colors or Numbers
56

57

Balance Chart

Future State/ Moveable wall to eliminate
crane usage

TUBULAR BELLS FLOW
60 Hours
120 Hours
120 Hours
Day 1 Day 7 Day 28
Day14 Day21
Ship
22 Days
Takt Stations
60 Hours
60 Hours
60 Hours

FMC modular flow guidelines 08-03-13

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