Balance, Bottlenecks, and Triggers … oh my! Dr. Lars Maaseidvaag MoreSteam.com.
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Transcript of Balance, Bottlenecks, and Triggers … oh my! Dr. Lars Maaseidvaag MoreSteam.com.
![Page 1: Balance, Bottlenecks, and Triggers … oh my! Dr. Lars Maaseidvaag MoreSteam.com.](https://reader030.fdocuments.in/reader030/viewer/2022032707/56649e4e5503460f94b4471b/html5/thumbnails/1.jpg)
Balance, Bottlenecks, and Triggers
… oh my!
Dr. Lars Maaseidvaag
MoreSteam.com
![Page 2: Balance, Bottlenecks, and Triggers … oh my! Dr. Lars Maaseidvaag MoreSteam.com.](https://reader030.fdocuments.in/reader030/viewer/2022032707/56649e4e5503460f94b4471b/html5/thumbnails/2.jpg)
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Agenda
• Welcome
• Introduction of MBB Webcast Series
− Larry Goldman, MoreSteam.com
• Today’s Session
− Lars Maaseidvaag, MoreSteam.com
• Open Discussion and Questions
![Page 3: Balance, Bottlenecks, and Triggers … oh my! Dr. Lars Maaseidvaag MoreSteam.com.](https://reader030.fdocuments.in/reader030/viewer/2022032707/56649e4e5503460f94b4471b/html5/thumbnails/3.jpg)
• Founded in 2000
• Trained over 370,000 Lean Six Sigma professionals
• Served over 2,000 corporate customers (including 50+% of the F500)
• First firm to offer the complete Black Belt curriculum online and only firm to offer online DfLSS
• Courses reviewed and approved by ASQ and PMI
• Academic Partnership with Ohio State University
MoreSteam.com
Select Customers:
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Lars Maaseidvaag
Senior Master Black Belt, MoreSteam.com
• Leads Lean curriculum development; MBB instructor
• Previous Curriculum Director for Accenture/George Group
• PhD in Operations Research from the Illinois
Institute of Technology; M.S. in Operations Research & Industrial Engineering as well as an MBA from The University of Texas in Austin
Today’s Presenter
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Copyright 2012 MoreSteam.com
You Say Tomato…
There are many terms used in Lean to refer to two, relatively simple concepts:
Capacityand Consumption
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Copyright 2012 MoreSteam.com
Capacity, a.k.a…Bottleneck, Time Trap, Herbie…
All of these names refer to the step in the process which defines the maximum capacity or throughput of the process – or more simply, the
RATE OF PRODUCTION
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Copyright 2012 MoreSteam.com
Consumption, a.k.a.Trigger, Takt Rate, Pacemaker Process…
All of these names refer to the RATE OF CONSUMPTION and where that consumption signal is delivered to the process
Analyzing consumption versus production is often accomplished with the Lean Takt Time analysis
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Copyright 2012 MoreSteam.com
Takt Time Analysis
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Copyright 2012 MoreSteam.com
Better 1, or Better 2?
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Copyright 2012 MoreSteam.com
Where to Send the Trigger?
A B C D E?
Considerations:Repetitive make-to-stock or make-to-order?Customer expectation of lead time?
The point where the trigger is received will set the pace or rhythm of the process, unless the process is capacity constrained!
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Copyright 2012 MoreSteam.com
Make to Finished Stock
A B C D E
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Copyright 2012 MoreSteam.com
Make to Semi-Finished Stock
A B C D E
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Copyright 2012 MoreSteam.com
Make to Order
A B C D E
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Copyright 2012 MoreSteam.com
Capacity Constrained
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Copyright 2012 MoreSteam.com
Questions?
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Copyright 2012 MoreSteam.com
What About Variation?
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Copyright 2012 MoreSteam.com
Adding Process Capability to Takt Time Analysis
We are only concerned with task times which go above takt time, so we areonly concerned with the Upper Spec Limit
Upper Spec Limit (USL) = Takt Time
CPU = (USL – Task Time Mean ) / 3 x Task Time Std Dev
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Copyright 2012 MoreSteam.com
A Four Step Process ExampleTakt Time 7
Mean Std Dev Cpu p(>TaktTime) p(<=TaktTime)Step 1 4 2 0.50 6.7% 93.3%Step 2 5 1 0.67 2.3% 97.7%Step 3 6 1 0.33 15.9% 84.1%Step 4 3 2 0.67 2.3% 97.7%
RTY: 75.0%
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Copyright 2012 MoreSteam.com
Independence?
Is each step of the process truly independent of the previous step?
Yes?
No?
Is each piece of work independent from the previous piece?
Yes?
No?
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Copyright 2012 MoreSteam.com
What About Demand Variation?
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Copyright 2012 MoreSteam.com
Adding Demand VariationTakt Time 7
Mean Std Dev Cpu p(>TaktTime) p(<=TaktTime)Step 1 4 2 0.50 6.7% 93.3%Step 2 5 1 0.67 2.3% 97.7%Step 3 6 1 0.33 15.9% 84.1%Step 4 3 2 0.67 2.3% 97.7%
RTY: 75.0%
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Copyright 2012 MoreSteam.com
Takt Time Analysis Simulation
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Thank you for joining us
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• Offered in partnership with Fisher College of Business at The Ohio State University
• Employs a Blended Learning model with world-class instruction delivered in both the classroom and online
• Covers the MBB Body of Knowledge, topics ranging from advanced DOE to Leading Change to Finance for MBBs
Master Black Belt Program
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Resource Links and Contacts
Archived presentations and other materials: http://www.moresteam.com/presentations/
Questions? Comments? We’d love to hear from you.
Dr. Lars Maaseidvaag, Senior MBB – MoreSteam.com [email protected]
Larry Goldman, Vice President Marketing – [email protected]
Join us for our next Webcast on October 31st:
“A3 Reports: Polishing the Elevator Speech” – Tor Chamberlain, Coplay