Cellular Manufacturing Designing and Implementing One Piece Flow in Manufacturing



Yüklə 461 b.
tarix26.07.2017
ölçüsü461 b.


Cellular Manufacturing

  • Designing and Implementing One Piece Flow in Manufacturing






One Piece Flow

  • …is a condition that exists when products move through a manufacturing process one unit at a time, at a rate determined by the needs of the customer.

  • The opposite of one piece flow is mass production with batches and queues



One Piece Flow Creates:

  • Quicker delivery

  • Reduction in storage and transportation.

  • Less damage, deterioration, or obsolescence.



Typical Manufacturing Cell



Working In A Cell

  • Operating in a U-Shaped Cell

  • Becoming Multiskilled, Multimachine Operators

  • Using Small, Flexible Machines

  • Using Autonomation (Jidoka) to Eliminate Machine Watching



Working in a Cell



Operating in a U-Shaped Cell

  • Reduce travel distance by arranging equipment and workstations closer together.

  • Beginning of process is closer to end of process….minimizes the travel distance for next cycle.



Steps of Cell Design



Document the Current Process

  • The basic steps to 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 Chart


Document the Current Process

  • Collect Product and Production Data:

    • Product Mix:
      • A high volume process tends to pull the maximum benefit from the improvement, while low variety avoids issues such as changeover.
      • Use pareto analysis (20:80 rule on product type/quantity) to determine high volume process.
    • Production Resource Data:
      • Shifts per day
      • Hours per shift; break time
      • Work days per month
      • Monthly product volume requirements from customer
      • Approach assigning work
      • Finished goods inventory turns per month


Document the Current Process

  • Document Current Layout and Flow:

  • Two activities are involved in understanding what operations make up the process and how that process is currently performed

  • Process Route Analysis:

    • Helps to identify processing similarities between different products and groups of products that could be made in a cell.
  • Process Mapping:

    • Use of Standard Work Sheet to process map the current layout and path of the products going through process.
    • Record distance the product must travel during processing.
    • Record quantity of WIP in the process at a given time.
    • Record number of people currently required to run the process.


Document the Current Process

  • Time the Process:

    • Use time observation sheet to collect the cycle time for each machine operation and work station in the process.
    • Determine a sample process lead time for the total process.
    • Determine the value-added ratio. The value-added ratio is the time spent actually machining or working on the product divided by the total process lead time.


Document the Current Process

  • Calculate Process Capacity and Takt Time:

  • Develop a Process Capacity Table to reflect the manual as well as the machine time for each operation in a process.

  • Calculate the Takt time. It is the pulse or the beat of the factory.



Document the Current Process

  • Create Standard Work Combination Chart:

  • Graphical display for each operation in the process.

  • Depict the relationship between manual work time, machine work time, and walking time for each step in an operation as well as the non-cyclical time.

  • Draw a solid line to indicate the Takt time.



Standard Work Combination Chart



Steps of Cell Design

  • Document the current process

  • Define the product family and calculate TAKT Time for the cell

  • Balance the work to create flow between work-stations that meets demand

  • Design the cell for ergonomics

  • Test and de-bug the cell design



Balance the Work to Create Flow

  • Use the operator balance chart

  • Use the standard work combination chart



Cycle Time / Takt Time Bar Chart



Cycle Time / Takt Time Bar Chart



Standard Work Combination Sheet

  • Used to:

  • Provide adherence to Standardized Work in the cell.

  • Train operators.

  • Display the best combination of operator and machine.

  • Displays the sequence of steps for an operator.





Standardized Work Layout

  • Visually displays the process at a glance

    • Machine Layout
    • Order of Operations
    • Work Sequence for a single operator
    • Standard Work in Process
    • Quality Checks
    • Safety Precautions




Design the Cell for Flow and Ergonomics

  • Team brainstorming to improve these 4 elements

  • Method

  • Machines

  • Materials

  • People



Designing the Cell

  • Plan Possible Layouts

    • Use the process sequence as basic principle.
    • Place everything as close together as possible.
    • Select cell configuration: U, C, Straight line, …, etc.
    • Counterclockwise is preferred flow for better control and efficient handling.
  • Move the Machines

    • For a smooth transition, team needs to discuss with production, maintenance, transport, engineering, and housekeeping.


Documenting the New Process

  • Revise the Standard Work Combination Chart to reflect the new cell staffing plan

  • Draft new standard operating procedures



Steps of Cell Design

  • Document the current process

  • Define the product family and calculate TAKT Time for the cell

  • Balance the work to create flow between work-stations that meets demand

  • Design the cell for ergonomics

  • Test and de-bug the cell design



Testing the New Process

  • Test run parts through the cell

  • Observe operation steps and timing

  • Re-distribute work to achieve balance



De-bugging

  • Monitor the new cell every day for 2-3 weeks

  • Provide a means to collect feedback from operators: flip chart, white board

  • Fix problems every day

  • Monitor performance against standard



: wp-content -> uploads -> 2009
2009 -> Issn 0143-6597 print/issn 1360-2241 online/03/020235-19
2009 -> «els» MÜSTƏQİl araşdirmalar məRKƏZİ «Əhalinin fövqəladə hallarda operativ xəbərdarlıq sistemi: mövcud problemlər və onların həlli yolları»
2009 -> Müstəqil Araşdırmalar Mərkəzi «Əhalinin fövqəladə hallarda operativ xəbərdarliq sistemi: mövcud problemlər və onlarin həlli yollari»
2009 -> Texto de apoio ao curso de especialização Atividade física adaptada e saúde Prof. Dr. Luzimar Teixeira eritema nodoso1[11]
2009 -> Opis projektu Analiza molekularna w chorobach neurodegeneracyjnych spowodowanych mutacjami dynamicznymi. Charakterystyka chorób spowodowanych mutacjami dynamicznymi
2009 -> Aansoeke sluit op 31 Oktober
2009 -> Official entry form
2009 -> Recto y ano : Recto y ano
2009 -> Cup of mint tea is an effective painkiller




Verilənlər bazası müəlliflik hüququ ilə müdafiə olunur ©azkurs.org 2019
rəhbərliyinə müraciət

    Ana səhifə