vandal boat factory simulation. outline review of lean concepts review the current state of vandal...
TRANSCRIPT
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Vandal Boat Factory Simulation
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Outline• Review of lean concepts• Review the current state of Vandal paper factory
– VSM– The products and practice
• Simulation 1– Role assignment– Execution and data gathering– Analysis
• Simulation 2– Review slides from day 4, transition to future state, calculating Takt time– Redesign– Execution and data gathering– Analysis
• Simulation 3– Review slides from day 4, pacemaker process, – Redesign– Execution and data gathering– Analysis
• Wrap up
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REVIEW
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House of Lean Thinking
Lean Champion SeriesContinuous Cost Reduction Through The Elimination of Waste
5S / Visual ManagementLevel Loaded Production
Just In Time
Operate with the minimum resource requirements to
consistently produce
• Just what is needed
• Just the required amount
• Just where it is needed
• Just when it is needed
JidokaBuilt in Quality
In station quality: never pass a bad part onto the next process.
• Poke Yoke (error proofing)
• Automatic line stops (andon)
• Man-Machine Separation
• Prevent Problems (controls)
• Root cause analysis (5 why’s)
Best Quality, Cost, Delivery, Safety Defects and
Morale (QCSDM)
• Decision making• Common goals• Cross-training• Selection
PEOPLE & TEAMWORK
WASTE REDUCTION
CONTINUOUS IMPROVEMENT (KAIZEN)
• Problem Solving• Eyes for Waste• Genchi Genbutsu: go to gemba
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Forms of Waste1. Defects2. Overproduction3. Waiting4. Non-Value Added Processing.5. Transportation6. Inventory (Time)7. Motion8. Employees - Knowledge, Skills and Abilities9. Energy and Environment
5
5%Value-Added
Waste
95%
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VANDAL PAPER BOAT FACTORY
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Principles of Lean Manufacturing
Round 1 (Traditional) Round 2 (Student Redesigned) Round 3 (Instructor Prompted)
SIMULATION
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Sells for $8
Labor cost:Facilities
cost:Material
cost:
$2.00/person/shift$1.00/sq ft/shift$.25/sheet paper
Sells for $8
Materials cost $0.50
Materials cost $0.50
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1. Sales Representative Processes “Customer Order”2. Production Scheduler Generates “Factory Order” from forecast3. Kitter(s) Organizes raw materials for “Factory Orders”4. Material Handler Moves product between ALL workstations
5. Folder I Initial folding: Green6. Folder I Initial folding: White7. Folder II Final folding : Green8. Folder II Final folding: White9. Logo Stamper (white)10. Logo Stamper (green)11. Oven Operator (white)12. Oven Operator (green)
13. Inspector (2) Assures Quality14. Reworker Repairs failed boats15. Warehouse/Ship Clerk Matches boats to “Customer Orders”16. Production Supervisor Supervises production17. Industrial Engineer (2) Monitors production process18. Trucker Ships products to the
customer
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White Paper
Green Paper
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1 piece
1 piece 1 piece
1 piece
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4 per batch
4 per batch
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Customerorderforms
Factoryorderforms
FinishedGoods
Warehouse
Customerorders
(demand)
Production forecast
Shipments to
customers
Production Scheduling Process
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4 minutes after order
4 minutes after order
All orders are filled “first-in, first-out” (FIFO)
Promised shipments to customersPromised
shipments to
customers
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Principles of Lean Manufacturing
• All shifts are 10 minutes• Keep busy at all times• Yell if you need parts• Handle all parts first-in, first-out
(FIFO)• Only the Material Handler can move
parts• Stay at your workstation• The boss is always right!
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Set-up
• Role assignment• Paper boat folding practice• Wet the line• IE data collection strategies/objectives
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Principles of Lean Manufacturing
Round 1
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Debriefing Questions
• What forms of DOWNTIME waste were experienced in the simulation?
• What opportunities exist for waste elimination through 5s/visual control?
• How were issues of load leveling experienced?• In what areas of the factory were product flow best? Most
problematic? Why?• What issues in product quality were encountered? What was
the root cause of these defects?• Which jobs were most stressful? In what ways? Why is it
important to engage workers in these positions in lean improvements?