DP-R1System for detection & response to production disruptions

FR-R1Respond rapidly to production disruptions

FR-R12Communicate problems to the right people

FR-R11Rapidly recognize production disruptions

DP-R12Process state feedback system

DP-R11Subsystem configuration to enable operator’s detection of disruptions

FR-R13Solve problems immediately

DP-R13Standard method to identify and eliminate root cause

FR-R112Identify disruptions when they occur

FR-R111Identify disruptions where they occur

DP-R112Increased operator’s sampling rate of equipment status

DP-R111Simplified material flow paths

FR-R122Supply descriptive info to support resources

FR-R121Identify correct support resources

DP-R122System that conveys nature of problem

DP-R121Specified support resources for each failure mode

FR-R123Minimize delay in contacting correct support resources

DP-R123Rapid information transfer system

FR-R113Identify nature of disruption

DP-R113Context sensitive feedback

Identifying and Resolving ProblemsFR-Q1

Stabilize process

DP-Q1Elimination of assignable causes of variation

FR-Q2Determine capability of process (est. process parameters)

DP-Q2 Measure current process

FR-Q3Improve capability of process

DP-Q3Design of experiments

FR-Q11Eliminate machine assignable causes

DP-Q11Selection/maintenance of equipment

FR-Q12Eliminate operator assignable causes

DP-Q12Stable output from operators

FR-Q122Operator consistently performs tasks correctly

DP-Q122Standard work methods

FR-Q121Operator has knowledge of required tasks

DP-Q121Training program

Quality

FR-Q13Eliminate method assignable causes

DP-Q13Process plan design

FR-Q14Eliminate material assignable causes

DP-Q14Supplier quality program

FR-Q123Ensure operator human errors do not translate to defects

DP-Q123Mistake proof operations (Poka-Yoke)

DP-P1Predictable production resources (people, equipment, info)

FR-P1Minimize production disruptions

FR-P12Ensure predictable equipment output

FR-P11Ensure availability of relevant production information

FR-P14Ensure material availability

FR-P13Ensure predictable worker output

DP-P12Maintenance of equipment reliability

DP-P11Capable and reliable information system

DP-P14Standard material replenishment system

DP-P13Motivated work-force performing standard work

FR-P133Do not interrupt production for worker allowances

FR-P131Reduce variability of task completion time

DP-P133Mutual Relief System with cross-trained workers

DP-P131Standard work methods to provide stabilized processing time

Predictable Output

FR-P132Ensure availability of workers

DP-P132Perfect Attendance Program

FR-D2Eliminate wasted motion of operators

FR-D1Eliminate operators waiting on machines

DP-D2Design of workstations / work-loops to facilitate operator tasks

DP-D1Human-Machine separation

FR-I1Eliminate managerial tasks

DP-I1Self directed work teams (horizontal organization)

FR-I2Eliminate information disruptions

DP-I2Seamless information flow (visual factory)

FR-D11Reduce tasks that tie the operator to the machine / station

DP-D11Machines & stations designed to run autonomously

FR-D12Enable worker to operate more than one machine / station

DP-D12Train the workers to operate multiple stations

FR-D21Minimize wasted motion of operators between stations

DP-D21Configure machines / stations to reduce walking distance

FR-D22Minimize wasted motion in operators’ work preparation

DP-D22Standard tools / equipment located at each station(5S)

FR-D23Minimize wasted motion in operators’ work tasks

DP-D23Ergonomic interface between the worker, machine and fixture

IndirectLabor

DirectLabor

DP- T3Reduction of transportation lot size (single-piece flow)

DP-T5Subsystem design to avoid production interruptions

FR-T53Ensure that support resources (people/automation) don’t interfere with one another

FR-T51Ensure that support resources don’t interfere with production resources

FR-T52Ensure that production resources (people/automation) don’t interfere with one another

FR-T3Reduce lot delay

FR-T5Reduce systematic operational delays

FR-T11Knowledge of demanded product mix (part types and quantities)

FR-T12Ability to produce in sufficiently small run sizes

FR-T1Reduce run size delay

DP-T1Production of the desired mix and quantity during each demand interval

DP-T11Informationflow from downstream customer

DP-T12Design quick changeover for material handling and equipment

DP-T53Ensure coordination and separation of support work patterns

DP-T51Subsystems and equipment configured to separate support and production access req’ts

DP-T52Ensure coordination and separation of production work patterns

DP-T2Production balanced according to takt time

FR-T2Reduce process delay(caused by ra > rs)

FR-T23Ensure that part arrival rate is balanced with service rate (ra=rs)

FR-T22Ensure that production rate is balanced with takt time(rs

max = 1/ttmin)

FR-T21Define takt time(s)

DP-T23Arrival of parts at downstream operations according to pitch

DP-T22Subsystem enabled to meet the desired takt time (design and operation)

FR-T221Automatic cycle time minimum takt time

FR-T222Manual cycle time takt time

DP-T223Stagger production of parts with different cycle times

FR-T223Ensure level cycle time mix

DP- T221Design of appropriate automatic work content at each station

DP- T222Design of appropriate operator work content/loops

DP-T21Definition or grouping of customers to achieve takt times within an ideal range

DP-T232Parts moved to downstream operations according to pitch

FR-T232Ensure proper timing of part arrivals

DP-T4Material flow oriented layout design

FR-T4Reduce transportation delay

DelayReduction

DP-T231Standard work in process between sub-systems

FR-T231Ensure that parts are available

FR1Maximize long-termreturn on investment

DP11Production to maximize customer satisfaction

FR113Meet customer expected lead time

FR112Deliver products on time

DP1ManufacturingSystem Design

FR11Maximizesalesrevenue

DP13Investment based on a long term system strategy

FR13Minimizeinvestment over production system lifecycle

DP12Elimination of non-value adding sources of cost

FR12Minimize productioncosts

FR-111Deliver no defects

DP-111Defect-free production processes

DP112Throughput time variation reduction

DP122Reduction of indirect labor tasks

DP121Elimination of non-value adding manual tasks

FR122Reduce waste in indirect labor

FR121Reduce waste in direct labor

DP123Reduction of consumed floor space

FR123Minimize facilities cost

DP113Mean throughput time reduction

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PRODUCTION SYSTEM DESIGN DECOMPOSITION

© MIT 2000DATE/TIME

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MSD Decomposition v5.0.pptFILENAME

04/21/23 05:56 PM

Professor David S. Cochran77 MASSACHUSETTS AVENUE, BUILDING 35-135CAMBRIDGE, MA 02139PHONE: (617) 253-1811 FAX: (617) 258-7488

PSDProduction System Design LaboratoryLaboratory for Manufacturing and ProductivityMassachusetts Institute of Technology

Facilitiescost

LEGEND

Characteristic relating to MRP II

FR - Functional Requirement

DP - Design Parameter