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TPS Cells and Manufacturing System Comparisons T. Gutowski

TPS Cells and Manufacturing System Comparisons T. Gutowski. Ref; J T. Black Factory with a Future McGraw-Hill 1991, Chapters 2 & 4 “The Monument of Monuments” from Lean Thinking, Womack & Jones 1996 5 homework problems due Nov 13th. Topics. Operation of cell; Standard work

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TPS Cells and Manufacturing System Comparisons T. Gutowski

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  1. TPS Cells and Manufacturing System ComparisonsT. Gutowski Ref; J T. Black Factory with a Future McGraw-Hill 1991, Chapters 2 & 4 “The Monument of Monuments” from Lean Thinking, Womack & Jones 1996 5 homework problems due Nov 13th Version 2; 10/27/02

  2. Topics • Operation of cell; Standard work • Increase in production rate • Video of cells • L, l & W for cell; L=lW • Design of cell • Comparison with job shop and flow line Version 2; 10/27/02

  3. Cell Features • “Synchronized”, sequential production • Operator decoupled from individual machines • Operator integrated into all tasks • Goal: single piece Flow • Best with single cycle automatics, but can be done manually too Version 2; 10/27/02

  4. Machining Cell Operator moves part from machine to machine (including “decouplers”) by making traverse around the cell. Video Version 2; 10/27/02

  5. Walking segments - 10 Machining Cell 6 5 7 8 4 9 3 10 2 1 Version 2; 10/27/02

  6. Parts in the cell ~ 14 Machining Cell 7 8 9 6 10 11 5 14 12 4 13 3 2 1 Version 2; 10/27/02

  7. Standard Work for Cell Cell produces one part every 153 sec Note: machine time Max (MTj) < cycle time CT i.e. 120 < 153 Version 2; 10/27/02

  8. To increase production rate add 2nd worker WORKER 2 WORKER 1 Version 2; 10/27/02

  9. What is the production rate for this new arrangement? Check max(MTj) < CT Worker 1; 70 < 77 Worker 2; 120 >76 One part every 120 seconds Can we shift work off of the HM to reduce the cycle time? Version 2; 10/27/02

  10. WORKER 2 WORKER 1 Version 2; 10/27/02

  11. Standard Work for Worker #2 Cycle # 1 Cycle # 2 Operator waiting On machine Version 2; 10/27/02

  12. What is the new production Rate? Check max(MTj) < CT Worker 1; 70 < 77 Worker 2; 90 > 76 Hence Worker #2 will be waiting on Vertical Mill #2 Version 2; 10/27/02

  13. What is the new production Rate? • The new production rate is; one part every 90 sec • Pro and Cons; Worker “idle”, can’t speed up by adding additional worker • Design for flexibility make; Max(MTj) < CT/2 Version 2; 10/27/02

  14. Alternative solution add 2 HM’s A B WORKER 2 WORKER 1 Version 2; 10/27/02

  15. What did you think of the operator’s job in the video? See B&S Video Seeta cave, Ellora, India Version 2; 10/27/02

  16. TPS Cell and Little’s Law • L =l W, we know L and l, what is W? • Define System Boundaries • Follow part around the cell • Single operator case Version 2; 10/27/02

  17. Number of round trips; 13 Machining Cell 7 8 9 6 10 11 5 12 4 13 3 2 1 1989 + 150 = 2139 Version 2; 10/27/02

  18. By Little’s Law L = (13 + 1) X 150/153) + 13 X (3/153) = 13.98 rate, l = 1/153 W = 153 X 13.98 = 2139 Homework #1 Determine L,l & W For the 2 operator Systems Version 2; 10/27/02

  19. Designing a cell for the “Rod Support” Goal one part every 2.5 minutes • Material; Aluminum extrusion • Tolerance + 0.005”, except for the two 0.50” radius corners which have + 1/64” Version 2; 10/27/02

  20. Cellular Layout (One operator) Cold Saw Radial Arm Drill Press Belt Sander Drill Press Version 2; 10/27/02

  21. Cellular Layout (One operator) Note; Times in minutes Version 2; 10/27/02

  22. Cold Saw .32+.05/.72 Belt Sander .8+.05/.4 Drill Press .55+.05/.04 Cellular Layout (One operator) RA Drill Press .47+.05/.24 Walking time Version 2; 10/27/02

  23. Standard Work for Rod Support Cell Note; Times in Seconds Version 2; 10/27/02

  24. 2.810 Homework; #2 Increase the production rate for this cell to one part every minute #3 After reading “The Monuments of Monuments”, answer; a) Calulate the production rate for each system b) How many cells are required to replace the Blohm grinder? Version 2; 10/27/02

  25. Other Layouts Job Shop Flow Line FMS Version 2; 10/27/02

  26. Job shop (Small quantities, Aluminum block) Version 2; 10/27/02

  27. Job shop (Large quantities, Aluminum extrusion) Version 2; 10/27/02

  28. CNC production, aluminum block Version 2; 10/27/02

  29. Flow shop (Unbalanced work load) Version 2; 10/27/02

  30. Flow shop (Improved work load) Version 2; 10/27/02

  31. Comparison Version 2; 10/27/02

  32. Cost Calculation without considering Inventory holding cost Version 2; 10/27/02

  33. Cost for increasing production volume C = F + V N Version 2; 10/27/02

  34. Lowest variable cost unless you further balance the Flow Shop 2 Cost for increasing production volume Version 2; 10/27/02

  35. Results Version 2; 10/27/02

  36. 2.810 Homework ; #4 design cell for this part at one part every 7 minutes, #5 redesign for one part every 4 minutes Dimensions in inches, surface in micro-inches Version 2; 10/27/02

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