EngineeringManagement

MSE507Lean Manufacturing

Cellular ManufacturingOne Piece Flow for Workteams

Chapter 3Basic Elements of Cell Design

Chapter 3 Overview

Phase 1 – Understanding the Current Conditions• Collect Product and Production Data• Document Current Layout and Flow• Time the Process• Calculate Process Capacity and Takt Time• Create Standard Work Combination Sheets

Phase 2 – Converting to a Process-Based Layout• Evaluate the Options• Plan Possible New Layouts• Move the Machines• Document the New Operating Procedures• Test to Confirm Improvement

Phase 3 – Continuously Improving the Process• Shorten Cycle Times• Shorten Changeover Times• Eliminate Product Defects• Reduce Equipment Failures

Summary

Converting Work Area into A Manufacturing Cell

Understanding the current conditions

Converting to a process-based layout

Continuously improving the process

Phase 1: Understanding the Current Conditions

Helps the conversion team determine what process to convert, and a base line to measure improvement.

Collect Product Data and Production Data• Product mix (momentum parts)• Production resources (shifts, hours, employees, volume)

Document Current Layout and Flow• Process Route Analysis• Process Mapping• Time The Process

Calculate Process Capacity and Takt Time Create Standard Work Combination Sheet

Phase 2: Converting to a Process-Based Layout

Collect Product Data and Production Data• Evaluate the Options• Methods• Machines• Materials• People

Plan Possible New Layouts• Layout in the process steps is the basic principle• Machines placed close together• U or C shape• Often Counterclockwise (R/H next to machine)

Move the Machines Document the New Operating Procedures Test to Confirm Improvement

Phase 3: Continuously Improving the Process

Rearranging the layout into a manufacturing cell is not really an end point - it is the beginning of continuous improvement

Look for problems that keeps the process from flowing:• Long cycle times• Product defects • Long changeover times• Equipment failures

Shorten Cycle Times Shorten Changeover Times

• Separate Internal and External Setup• Convert Internal Setup to External Setup• Streamline All Aspects of Setup

Eliminate Product Defects• Mistake proofing/Zero Quality Control (ZQC)

Reduce Equipment Failure

Quiz 1Circle the best answer

1. The conversion from an operation-based factory layout to cell manufacturing has the following three basic phases:A. Understanding current conditions, converting to process-based

layout, and continuously improvingB. Understanding current conditions, converting to operation-based

layout, and continuously improving C. Learning from the past, keeping tribal knowledge, and resisting

changeD. Understanding future goals, converting to process steps, and

documenting them

2. Phase 1 is used to: A. Convince management to spend more money for improvementsB. Reduce resources needed to perform the workC. Give a baseline for measuring improvementD. Collect data so people can stay busy

Quiz 2Circle the best answer

3. Phase 2 is used to:A. Evaluate ways to improve methods, machines, materials, and people.

B. Time the process steps of one cycle of each machine

C. Measure distances travelled to perform the work

D. Interview the employees to understand their problems

4. One of the actions taken in phase 3 is: A. Shorten cycle times

B. Reduce headcount of employees needed

C. Creation of Standard Work Combination Sheet for each operation in the process

D. Creation of control charts to track attendance and performance

Summary

Phase 1 – Understanding the Current Conditions• Collect Product and Production Data• Document Current Layout and Flow• Time the Process• Calculate Process Capacity and Takt Time• Create Standard Work Combination Sheets

Phase 2 – Converting to a Process-Based Layout• Evaluate the Options• Plan Possible New Layouts• Move the Machines• Document the New Operating Procedures• Test to Confirm Improvement

Phase 3 – Continuously Improving the Process• Shorten Cycle Times• Shorten Changeover Times• Eliminate Product Defects• Reduce Equipment Failures

Questions? Comments?

EngineeringManagement

MSE507Lean Manufacturing

Cellular ManufacturingOne Piece Flow for Workteams

Chapter 4Teamwork Tools for Cellular Manufacturing

Chapter 4 Overview

Working in Teams

Standardizing Workplace Conditions through 5S

Using Visual Management for Production Control

and Safety

Performing Autonomous Maintenance Activities

Using Activity Boards and One-Point Lessons

Summary

Working in Teams

Success depends on teamwork In a cell, people work together in new ways Several operations are combined in a sequence, and the

main job of the people working in the cell is to maintain a smooth flow through the operations

Work must be coordinated A group of employees has more creative potential and

energy than any person working on a problem alone

Standardizing Workplace Conditions through 5S

Cellular manufacturing cannot succeed in a workplace that is cluttered, disorganized or dirty

Establishing basic workplace conditions is essential in creating a manufacturing cell

The 5S system is a set of five basic principles that have names beginning with S:• Sort• Set in Order• Shine• Standardize• Sustain

Using Visual Management for Production Control and Safety

Visual management is an important support for cellular manufacturing Visual management techniques express information in a way that can

be understood quickly by everyone Sharing information through visual tools helps keep production

running smoothly and safely One form of visual management in manufacturing cells is the andon

system:• Individual machines or assembly stations are equipped with call lamps

• If the machine breaks down or run out of parts, the operator or the machine turns on a light to call attention

Visual location indicators help keep order in the workplace• Lines, labels, and signboards

Visual information can also prevent to make mistakes• Color coding

• Matching color marks

Performing Autonomous Maintenance Activities

Activities carried out by shopfloor teams in cooperation with maintenance staff

Element of Total Productive Maintenance (TPM) Changes old view that operators just run machines and

maintenance people just fix them Operators learn how to clean the equipment daily and how

to inspect it for trouble signs as they clean Learn the equipment and assist with repairs Team-based activity: work with maintenance technicians

and engineer

Using Activity Boards and One-point Lessons

Two useful approaches for making information public A bulletin board or wall chart

• Displays information about team activities and the results achieved• Chart improvement measures such as quality rate, On Time

Delivery, First Time Yield, Overtime, Takt Rate, etc.• Helps keeping track of issues to follow up in the future

A one-point lesson • An easy to read poster to teach others about a particular problem• An improvement example, or • Basic knowledge that everyone should have• Kept short and focused on one point • Often illustrated with photos or drawings

Quiz 1Circle the best answer

1. The main job of people working in a cell is to:A. Ensure there is always one person resting while others work

B. Maintain a smooth flow through the operations

C. Keep the equipment and machines in good shape

D. Keep producing parts and be busy all the time

2. The 5S system is a set of five basic principles: A. Sort, Set in Order, Shine, Stabilize, Sustain

B. Sort, Set in Order, Self-Control, Stabilize, Sustain

C. Sort, Set in Order, Shine, Standardize, Sustain

D. Sort, Set in Order, Simulate, Standardize, Sustain

Quiz 2Circle the best answer

3. Visual management techniques express information in a way that can be:A. Understood quickly by management

B. Understood quickly by customers

C. Can be understood quickly by everyone

D. Can be understood quickly by only the cell employees

4. Autonomous maintenance refers to shop floor team activities: A. To help stabilize basic equipment conditions and spot problems

B. To help the maintenance crew when one of them is sick

C. To control what is done on the machines they have in the cell

D. To give autonomy to the maintenance of each machine

Summary

Working in Teams

Standardizing Workplace Conditions through 5S

Using Visual Management for Production Control

and Safety

Performing Autonomous Maintenance Activities

Using Activity Boards and One-Point Lessons

Homework Assignment

1. What did you learn from chapter 3 that stands out as particularly useful or interesting?

2. What did you learn from chapter 4 that stands out as particularly useful or interesting?

Finalize Project Presentation & Report Complete Research Assignment Peer Review Report Start to study for final exam

Questions? Comments?