Self-Balancing: True continuous flow

Gordon L. Ghirann, Lean Specialist

Through the Eyes of an Expert

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Self-Balancing: True continuous flow

Gordon L. Ghirann, Lean Manufacturing Specialist

Through the Eyes of an Expert

PARTNERS BY DESIGN

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ The last 100 years

„ Myths

„ Self-Balancing

„ Video examples

„ Live demonstration

„ Challenges to Self-Balancing

„ Q & A

Agenda

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

• Level Loading

‟ Dividing up the work evenly among each Operator

• Highlight waste at each station/Operator

‟ Focus on discrete processes

• Everybody works to TAKT

‟ The line runs at a steady pace

• WIP buffers

‟ Extra inventory between stations to account imbalances

Conventional Continuous Flow

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Operations

T/T

0

10

20

30

40

50

60

70

80

90

100

1 2 3 4 5 6 7 8 9

OP 1

OP 2

OP 4

OP 3 OP

5

OP 6

OP 7

OP 8

OP 9

Rough Turn

Finish Turn

Deburr Mill Slots

Deburr Drill Holes

Inspect Wash Grind

Time

Percent Loading Chart

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Operators

1. Rough Turn

2. Finish Turn 3. Deburr

5. Deburr

8. Wash

T/T

0 10

20 30 40

50 60 70 80

90 100

A B C

OP 1

OP 2

OP 4

OP 3 OP 5 OP 6

OP 7

OP 8

OP 9

4. Mill Slots

6. Drill Holes 9. Inspect

7. Grind

Time

Level Loaded

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

exit

Machine

Sequence

1

2

3

4

5

6

7

8

9

Work sequence

3

2

1

4

5

Operator A

1 2

Operator B

2

1

Operator C

The order in which an Operator performs manual operations.

Standard Work Sequence

entrance

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

What about the experience of the

Line Worker?

Conventional Continuous Flow

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Artificially balanced

„ Can’t handle variations in yield, cycle time, and demand (without adding waste)

„ Designed-in waiting

„ In-Process queues (WIP)

„ Silo mentality (factory condo)

„ Difficult to adjust output, inflexible

„ Absenteeism can shut down line

„ “Slowest” Operator/station (Herbie) sets the pace!

„ Repetitive, dehumanizing work

„ Social cost

What Really Happens

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Myth #1:

“Assembly lines work to TAKT”

Conventional Continuous Flow

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Myth #2:

“Level Loading can lead to

Continuous Flow”

Conventional Continuous Flow

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

What if your primary goal was

to achieve continuous flow?

Ripe for Improvement

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Get rid of any In-Process queues

„ Get rid of any waiting

„ End of the line would trigger the pull

„ Abandon trying to level load

„ Get rid of the chairs so people can move

„ Never set the part down

True Continuous Flow?

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

T/T

OP 1

OP 2

OP 4

OP 3 OP

5

OP 6

OP 7

OP 8

OP 9

0

10

20

30

40

50

60

70

80

90

100

A B C D E F G H I Rough Turn

Finish Turn

Deburr Mill Slots

Deburr Drill Holes

Inspect Wash Grind

Operations

Time

Original Arrangement “Un-Level Loaded”

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Self-Balancing: True Continuous Flow

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

PER CELL

Batch &

Queue

Level

Load

Self-

Balance

Overall %

Improved

Productivity (unit/hr-person) 0.30 0.35 0.56 87%

WIP inventory 810 80 24 97%

Lead Time (days) 10 3 0.7 93%

Cumulative Yield* 64% 65% 83% 19%

Space (sq. ft) 750 550 550 27%

Walking Distance (ft) 525 270 250 52%

Part Travel Distance (ft) 493 152 140 72%

*Simultaneous yield improvement projects implemented, highly sensitive to product mix

60% gain

Self-Balancing Results: Micro-Optic Assembly Line

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Keep building (progressively) until someone pulls from you

„ When the downstream person pulls from you, walk

upstream until you run into someone, then pull from them

„ If you catch up to someone, wait

„ Don’t “leapfrog”, everyone stays in their position

„ Communicate, Communicate, Communicate!

Self-Balancing Rules

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

9

7

8

6

1

2

4

3

5

exit

Operator B

Position 2

Operator A

Position 1

Operator C

Position 3

Work content may vary slightly each cycle

Operators work in positions (not a “rabbit chase”)

Self-Balancing Work Sequence

entrance

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

3 VOLUNTEERS

Live Demo

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Eliminates waiting (optimal division of work)

„ Simple, eloquent, flexible „ Operator paced (unleash your all-stars) „ No WIP Buffers

„ Operators, not parts, accumulate

at problems „ Silo’s disappear „ Increased yield

„ Reduced Secondary Labor support „ No more line balancing! „ A bias towards flow

Self-Balancing Features and Benefits

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Progressive Assembly/Processing horizontal parts and tools presentation

„ # of stations > # of Operators

„ Standard Work (the real thing!)

„ Infinite hand-off points

„ Contiguous x-training

„ Standing/walking line

(for maximum productivity ergonomics)

Requirements of Self-Balancing

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Task 1 Task 2 Task 3 Task 4 Task 5

Operator

A X X

Operator

B X X X

Operator

C X X

Contiguous Cross-Training Matrix

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Getting rid of the chairs

„ Fatigue

„ Low TAKT, “clumsy” hand-offs

„ Debugging

„ Highlighting waste at a station

Challenges to Self-Balancing

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ Anywhere there are queues

„ Anywhere there is a standard sequence

„ Mixed Model

„ Anywhere there are balance issues

‟ Business Processes

‟ Product Development

‟ Transactional Processes

Where Does Self-Balancing Apply?

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

„ 30-100% Productivity Gains

„ WIP Reduced 50%

„ Lead Times Reduced 50%

„ Improved Yields

„ Improved Employee Satisfaction

‟ Dynamic, diverse work

‟ Easier Cross-Training

‟ Improved communication

‟ Real teams

„ Reduced Social Cost

Honoring Workers, Honoring Results

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

Are We Self-Balancing Yet?

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

About Gordon L. Ghirann: Gordon L. Ghirann is a lean manufacturing specialist at JDSU, a leading provider of optical products and test and measurement solutions for the communications industry. It was while working as a manufacturing engineer at Kilovac, that Ghirann first discovered the self-balancing process. Ghirann describes self-balancing as a process that encourages communication and collaboration among workers within a team-based environment, thereby eliminating the need for self-pacing. By successfully implementing the self balancing method at numerous companies and industries around the world, Ghirann has helped reduce COGs, alleviate the human-cost of manufacturing, and improve quality control. He received his B.S. in Mechanical Engineering from Cal Poly, San Luis Obispo, and is a regular top presenter at the annual Association of Manufacturing Excellence (AME) conference. This fall, Ghirann is releasing his book, Self-Balancing Processes: True Lean Continuous Flow, the culmination of 13 years of manufacturing practice and research. For information on his book visit: http://www.crcpress.com/product/isbn/9781439819654;jsessionid=qoZi8qivnpODhHhsyjg1Lw Ghirann offers workshops in which participants learn how to set up a self-balancing line, from simple to complex manufacturing environments. He is also available for consultation to assess how your company could benefit from the self-balancing process. Contact information: (707) 799-0942 selfbalancing@gmail.com

Closing Slides

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©2011 Speck Design Through the Eyes of an Expert 03/31/2011: Gordon L. Ghirann

About Speck Design: For 15 years, Silicon Valley companies have turned to Speck Design to develop breakthrough products in medical, industrial, consumer and data communications. Our growth comes from repeat business and referrals, and our teams consist of trusted experts whom our clients rely on project after project, year after year. Services we offer include research, industrial design, engineering, testing and transfer to manufacturing. Known for reliability, flawless execution by fearless designers, and solutions that help grow our customers’ sales, Speck Design delivers a “partners by design” relationship in every product design project. To learn more, go to www.speckdesign.com Contact information: (650) 462-9080 info@speckdesign.com 3221 Porter Drive, Palo Alto, CA 94304

Closing Slides