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Transcript of 5-Lecture 5 Slides
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WORK CELL DESIGNWORK CELL DESIGN
Principles for Implementing Lean Manufacturing
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Cellular Flow
Definition
Cellular Flow Manufacturing is a method of
organizing manual and machine operations in the
most efficient combination to maximize value-added
content and minimize waste.
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Cellular Flow
Lean Building Blocks
Quick
Changeover
StandardizedWork
BatchReduction
Teams
Quality at
Source
5S System Visual Plant Layout
POU
S
Cellular/FlowPull/Kanban TPM
ValueStreamMapping
Continuous Improvement
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Cellular Flow
Cellular Manufacturing Benefits
Simplified scheduling and communication Minimal inventory needed between processes
Increased visibility
provide quick feedback and problem resolution
Development of increased product knowledgeDevelopment of increased product knowledge
workers are trained to understand the totalworkers are trained to understand the total
processprocess
Shorter lead timesShorter lead times
Small lots and one piece flowSmall lots and one piece flow
to match customer demandto match customer demand
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Work CellWork Cell Realization of a Lean ProcessRealization of a Lean Process
A work cells effectiveness is not separable from relatedA work cells effectiveness is not separable from relatedelements:elements:
-- The product(s)The product(s)
-- Workers must be able to manufacture and assemble theWorkers must be able to manufacture and assemble the
product to meet customer demandproduct to meet customer demand [DFA, DFM][DFA, DFM]
--A breadth of products often must be accommodated by aA breadth of products often must be accommodated by asingle manufacturersingle manufacturer [Product families][Product families]
-- The people(s)The people(s)
-- Work cells must produce varying products and varying ratesWork cells must produce varying products and varying ratesto meet customer demandto meet customer demand [Product families, Takt time][Product families, Takt time]
-- Work cells must be designed such that workers can safelyWork cells must be designed such that workers can safelyand repeatedly perform necessary steps to meet customerand repeatedly perform necessary steps to meet customerdemand.demand. [Human factors][Human factors]
Principles for Implementing Lean Manufacturing
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Cellular Flow
The Five Step Cell DesignProcess
Group Products
Establish Takt Time
Review the Work Sequence
Balance the Process
Design the Cell Layout
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Cellular Flow
Product Grouping Tool:The Product/Process Matrix
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Product PortfolioProduct Portfolio
The set of different product offerings that aThe set of different product offerings that a
company provides. Products can be unique, sharecompany provides. Products can be unique, sharecommon systems, and/or production methods.common systems, and/or production methods.
Product portfolio architectureProduct portfolio architecture system strategysystem strategyfor layout out components and systems onfor layout out components and systems onmultiple productsmultiple products
3 Portfolio Architectures3 Portfolio Architectures
1.1.Fixed unsharingFixed unsharing each product is unique, no sharingeach product is unique, no sharingof components, typically very high volumeof components, typically very high volume
2.2.Modular platformModular platform -- share modules, components, orshare modules, components, or
systems to meet the needed varietysystems to meet the needed variety -- commoncommonelements are called the platform and each supportedelements are called the platform and each supported
product is called a variantproduct is called a variant
3.3.Massively customizableMassively customizable varies to meet customervaries to meet customerneedneed either by customer (e.g. car seat) oreither by customer (e.g. car seat) or
manufacturermanufacturer
- Otto and Wood, 2000
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Cellular Flow
The Five Step Cell DesignProcess
Group Products
Establish Takt Time
Review the Work Sequence
Balance the Process
Design the Cell Layout
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More on Takt TimeMore on Takt Time
Takt time can change!!Takt time can change!!
What can you change to match takt time?What can you change to match takt time?-- Number of peopleNumber of people
-- Number of cells (requires investment in machinery)Number of cells (requires investment in machinery)
Takt Time Rounding Rules:Takt Time Rounding Rules:
Crew sizeCrew size calculation for an assembly line doing one piececalculation for an assembly line doing one pieceflow paced to Takt Time is:flow paced to Takt Time is:
-- Crew size = Sum of ManualCycle Time / Takt TimeCrew size = Sum of ManualCycle Time / Takt Time
If Manual Cycle Time = 1,293 seconds and a Takt time =If Manual Cycle Time = 1,293 seconds and a Takt time =345 sec345 sec
Crew size = 1,293 personCrew size = 1,293 person--seconds / 345 secondsseconds / 345 seconds Crew size = 3.74 peopleCrew size = 3.74 people
In this case the crew size will be 4 people since 3 peopleIn this case the crew size will be 4 people since 3 peoplewould not be able to meet customer demand.would not be able to meet customer demand.
Cellular Flow
Example from
http://www.gemba.com/uploadedFiles/Know%20Your%20Takt%20Time.pd
f
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Cellular Flow
The Five Step Cell DesignProcess
Group Products
Establish Takt Time
Review the Work Sequence
Balance the Process
Design the Cell Layout
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Cellular Flow
Steps in the Process
Observe and document the tasks each worker performs
- Observe, dont just ask
- The steps are defined (explicitly or implicitly) by the
designer
Break operations into observable segments
Study machine capacity, cycle times, and changeover
times Look for value-added and non-value-added elements
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Cellular Flow
The Five Step Cell DesignProcess
Group Products
Establish Takt Time
Review the Work Sequence
Balance the Process
Design the Cell Layout
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Cellular Flow
Combine Work to Balance the Process
0
0
0
0
0
0
60
Second
s
1 2 3 4 5
Operation Work Content
Before
0
10
20
30
40
50
60
Seconds
1 2 3 4
Operation Work Content
After
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Cellular Flow
Standard Work Combination Sheet Example
Date: 8/20/00
Manual Auto Walk
1
4 2 2
24 11 2
36 2 2
14 4 6
Part Name: Circulation Pump Takt Time: 27 seconds
Step #Work Content Time
Description
Work Content Graph (1.5 sec/div)
Manual
Machine
Walking
Work Sequence: 7 of: 15 Quota: 1,000 per shift
Total = 24
Pick up shaft and rotor;
load, assemble, unload
Unload, load, start
Pick up 2 nuts & bracket;
load, assemble, unload
273 6 9 12 15 18 21 24
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Cellular Flow
Alternative Work Combinations
Market demand = 220,000 units per yearTakt time = 27 seconds
Lathe Mill Mill InspectDrill
Drill
TestDrillPack
1 2 3 4 5
10 9 8 7
6
27
seconds 27
seconds
Inspect
27
second
s
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Cellular Flow
Staffing For Increased Demand
Market demand = 312,000units per yearTakt time = 19 seconds
Lathe Mill Mill InspectDrill
Drill
TestDrillPack
1 2 3 4 5
10 9 8 7
6
Inspect
19
seconds
19 seconds
19
seconds
19
seconds
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Cellular Flow
The Five Step Cell DesignProcess
Group Products
Establish Takt Time
Review the Work Sequence
Balance the Process
Design the Cell Layout
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Cellular Flow
Design Goals for All WorkAreas
Flexible output
Lot size of1
Point of Use Storage (POUS)
Mixed models
Visual management
Source inspection
Zero NVA activities
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Cellular Flow
Water Pump Case StudyWater Pump Case Study
Circulation Pump Assembly Cell
Bearing
Assy
MotorAssy
Solder
Make
Box
PackTestFinal
Assy
WindBobbin
Weld
ContactAssy
Rivet
BracketAssy
RotorAssy
Lathe
BobbinAssy Terminal
Assy
StatorAssy
)
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Cellular Flow
Water Pump Case Study
Testing
Packaging
Bobbin
Winding
New U-Shaped Cell
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Cellular Flow
Water Pump Case StudyWater Pump Case Study
Workplace Organization
Material flow chutes
Tools within reach
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Cellular Flow
Water Pump Case StudyWater Pump Case Study
Machining andAssembly
Material Flow Chute
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Cellular Flow
Ergonomic Factors in Work Station (andProduct) Design
Design the work to:
Minimize motionAvoid natural postures
and movements
Avoid sharp turns in motion Make moves easy to perform
without much concentration
Use hands and forearms insteadof upper arms and shoulders
for light work Minimize lifting Follow a rhythm
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Cellular Flow
Tool and Material Design andLayout Guidelines
Place tools and materials close to and in front of the
operator
Keep tools and materials in a designated place
Design fixtures for specific purposes, not general purposes
Combined usage tools are recommended when more than
one tool is required
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Cellular Flow
Ergonomic Resources
Ergonomic resources
are understandable,
practical, andaffordable.
Fitting the Task to the Man: An
Ergonomic Approach - Grandjean
The Measure of Man and Woman:
Human Factors in Design Tilley
and Dreyfuss
Your FE Resource Guide
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Cellular Flow
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Cellular Flow