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Creating Connected Process Flow

Creating Connected Process Flow. MHR 5350. Just-in-Time. Right part Right amount Right time Right place. One-piece Flow. Products are processed and moved directly to the next process one piece at a time. “Flow where you can. Pull where you can’t. Don’t Push!”. Flow Continuum.

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Creating Connected Process Flow

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  1. Creating Connected Process Flow MHR 5350

  2. Just-in-Time • Right part • Right amount • Right time • Right place

  3. One-piece Flow • Products are processed and moved directly to the next process one piece at a time

  4. “Flow where you can. Pull where you can’t. Don’t Push!”

  5. Flow Continuum

  6. Push – Batch & Queue Process A Process B Process C End User Elapsed time: 33 seconds

  7. Pull – Continuous Flow Process A Process B Process C End User Elapsed time: 15 seconds!

  8. Tools to Establish One-Piece Flow • Pull techniques • Supermarkets/Kanban • Sequenced Pull • Workplace/Cell design • Clearly defined customer/supplier relationships • Visual controls

  9. Pull • Defined agreement with specified limits pertaining to • Volume of production • Model mix • Sequence of model mix • Dedicated • Controlled

  10. Pull Example: Simple Process

  11. Pull Example: Three Distinct Models

  12. Pull Example: High Product Variety

  13. In the Office…Flow issues? Handoffs: Jobs moving through depts. (inbox) Waiting (Approvals, etc.) Transaction Waste Re-Invention Waste Lack of ‘System Discipline’ High Process and Arrival Variation System Over/Under-Utilization and Expediting Ineffective or Barriers to Communication Redundant Tasks “Stop and Go” Tasks Useless Information (e.g., e-mails, etc.) Designing features the customer doesn’t need Not utilizing resources to their full potential

  14. Kanban • Signal/Sign/Card • Visual control system used to trigger activity in upstream process • Replenishment for production and material • Usually printed card • Part number/description • Quantity • Location • Picture • Etc.

  15. Kanban Uses • Instruction • Self control to prevent overproduction • Visual control • Reduction of managerial cost • Reduction of inventory

  16. Kanban Advantages • Processes connected • Eliminates excess inventory • Floor space • Wasted material during model changeover • Boxes/bins/returnables • Potential problem: people

  17. Kanban Rules • Downstream process should withdraw the right parts from the upstream process at the right quantity and right time • Upstream process should produce the parts in the quantities withdrawn by the downstream process • Defective products should never be transported to the downstream process • Number of kanbans should be minimized • Kanban can be utilized to adapt to small variation in production volume • Actual quantity of parts in bin/box/pallet must be equal to the quantity on kanban

  18. Kanban Example

  19. Kanban Example

  20. Kanban Example

  21. Kanban Example

  22. Think • If some problem occurs in one-piece flow manufacturing then the whole production line stops. Why is that a good thing?

  23. Advantages of One-Piece Flow • RAPID CONTINUOUS IMPROVEMENT • Build in quality • Increased flexibility • Higher productivity • Decreased floor space • Improved safety • Improved morale • Reduced inventory

  24. Project Assignment • Create current state map (45-60 minutes) • Present current state map

  25. Questions?

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