introduction of flow management in manufacturing - addvalue - nilesh arora

7/23/2019 Introduction of Flow Management in Manufacturing - ADDVALUE - Nilesh Arora

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Best Performing Consulting Organization

by

Flow Management

AddingValueInTotality


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The World of Batch-and-Queue In traditional manufacturing, there is a tendency to

run large lots, or bat!"es. This occurs for a varietyof reasonslarge distances between #ro!esses, longsetup times, or simply poor processes.

When the batch is transferred to the downstream#ro!ess, it sits in line, the part of batch and ueue.

Batching and ueuing tends to drive up in$entoryand lead time, and creates ine%!ien!yin anoperation. It also increases the s#a!e neededforproduction.
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Traditional Met"od


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The World of Batch-and-Queue &"at "a##ens w"en you go to your do!tor'

!a"e appointment days ahead

#rrive on time and wait in waiting room

$octor behind schedule

%eferral to a specialist &aboratory tests

Wait for results

Treatment or medication given

Trip to pharmacy or to specialist

'ospitali(ation ) whole new disconnected processes andwaiting

&"at "a##ens w"en you ta(e a )ig"t' &"at "a##ens w"en you build a !ustom "ome'

#s the customer, you pay for all the waiting and rewor"


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*vils of Batch-and-Queue

Increases wor"-in-process inventory

'ides ine+ciencies, lost

opportunities &engthens replenishment cycle

reates nished good inventory

lows customer response time

%is"s obsolete products


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T"e *ltimate Fa!tory


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Continuous Flow

4roducing and moving one item at a time 5or a smalland consistent batch of items6 through a series ofprocessing steps as continuously as possible, with eachstep ma"ing 0ust what is reuested by the ne7t step.

It is also called the one-piece fow, single-piece fow,and make one, move one.

The intent of 2ow production is to increase the velocity

of products and ma"e the production cycle predictable.


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teady 8elocityTraditional:Batch Production (like a meandering stream with many stagnant pools, waterfalls, and eddies)

FLO:Production: Pipeline with fast!flowing water or product

The right "o# and it must keep mo$ing

% &&'hen do we get our Parts*


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Continuous FlowProdu!tion

+emem#er

Make It Flow Feed the Flow

Link the Flow


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What to 9low /.....


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even 9lows in!anufacturing The 2ow of raw material

The 2ow of wor"-in-process

The 2ow of nished goods

The 2ow of operators

The 2ow of machines

The 2ow of information The 2ow of engineering


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Value

+trea

mAnaly

sis

&aste

8! - to identify

8alue in treamIdealIdeal

OnePie!eFlow

+tandard&or(

,+ Pull

Future+tate

Future+tate

Current

+tate

Curre

nt+tate


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B83 :;

8alue tream !apping

8alue stream mapping is theprocess of mapping the currentand future status of process.

It maps both material andinformation 2ow.

This mapping is very clear and can

be used as an aid to developimplementation plan for installinga lean system.


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B83 :

8alue tream !apping

8isuali(e 2ows

Identify areas of wor"

reate a common language fortal"ing about the manufacturingprocess

4ull together lean thin"ingprinciples

Illustrate relationships between

information and physical 2ows

It helps to


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:. %edesign layout for 2ow

This complicated 2ow becomes a muchimproves and simpler 2ow between areas that

are adding value


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&ayout changeBeore ear

-o##ing

./. LatheBoring .hamfer ear

ha$er

0#ur1

-ole

Boring

2anual

0e#urring

Tooth

.hamfer

ear

ha$ingAter

./. Lathe

./.Lathe

-oning

./. 2ill

2ill 0rillBoring

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.ha

mfe

r

ear

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./. Lathe

-oning./. 2ill

2ill0rill

Boring

-o#

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ha$er

0#ur1

Blank 2achining

Blank 2achiningBore -oning

0ri$e lot2illing Lu#e lot

2illing

-ole

0rilling

-ole

Boring

2anual

0e#urring

ear

-o##ing

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.hamfer

ear

ha$ing

3n Out


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B83 ??

@. Balance wor"station capacities

!odel mi7

8olume

cheduling system

&abour

9i7ed facilities

apacities

ycle time

Balancing is important in practice andmust ta"e into following in to account.


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B83 ?@

;. Total 4roductive !aintenance

T4! aims to achievezero breakdowns &stoppages.

T4! aims to solve all the conseuences

of euipment problems. T4! aims to ma7imise equipment

eectiveness.

T4! establishes a thorough system ofpreventive maintenancefor theeuipmentDs entire life span.


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A

A A B B B C

.IT +mall /ots

/arge0/ot A##roa!"

Time

Time

A A B B B C

A A A B B B B B B C C

.IT #rodu!es same amount

in same time if setu# timesare lowered


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introduction of flow management in manufacturing - addvalue - nilesh arora

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