FMC modular flow guidelines 08-03-13

© 2009 Duggan Associates. All Rights Reserved.1

FMC MODULAR FLOW PRINCIPLES

Duggan Associateswww.dugganinc.com

08/03/2013

http://www.dugganinc.com/


• 20 Principles of Flow• Foundations

• Safety• TPM• 5S

• Tooling Presentation• Material Presentation • Flow through High Bay



• 20 Principles of Flow



FMC Modular Flow Principles

Within each Workstation:•No Safety violations•No forklifts, no cranes, no hoists•No trash containers in production areas•No pits, no platforms•No process flow reversals•Mistake-proofing; •Color coded go, no-go gages•Everything must be less than 1.5 meters (5 feet) in height•Visual Boards to show if station is on time•Product and Operators do not leave the cell or line•Daily equipment checks and TPM carried out routinely, no unplanned equipment downtime that reduces available working time•Quality issues are identified and addressed.


FMC Modular Flow Principles Across the Flow of High Bay:11.One-Piece Tree Flow12.Value Stream Map exists that show the new designed flow13.Inspection processes upstream in modules14.Modules built in parallel15.Systems and Standard Work in place to prevent part shortages16.Cross training is achieved; everyone can do everything, based upon and know if they are on-time17.Pitch used to pace the process18.Visual Boards showing performance metrics 19.Plans for when flow breaks down20.Management teaching and guiding on flow principles


Foundations for Modular Flow

• Safety• Non-Negotiable• Health, Safety, Environment

• TPM• 5S


Non-Negotiable Health, Safety, Environment


Non-negotiable Safety Reqs. •Fire extinguishers will be clearly marked by class (A, B, C) and will meet NFPA standards. Extinguishers with gross weight not exceeding 40 pounds should be installed so that the top of the extinguisher is no more than five feet above the floor.•Electrical breakouts will be clearly marked and have a 36” inch clearance and be free of obstruction per OSHA guidelines •Egress walkways will be free of obstruction and parking areas for equipment and tooling and will be clearly marked. •All flammable chemical cabinets will be grounded per 29 CFR 1910.106 and clearly marked with picture of cabinet contents as well as FIFO system to avoid use of expired chemicals.


Non-Negotiable

• Fire extinguishers will be clearly marked by class (A, B, C) and will meet NFPA standards. Extinguishers with gross weight not exceeding 40 pounds should be installed so that the top of the extinguisher is no more than five feet above the floor.


HAZMAT Control/ Chemical Handling Visual Coding of

expiration Type/MSDS info and expiration are clearly marked


Chemical Cabinet 5S

• Chemical cabinet should have picture of contents and display proper and in-proper condition


TPM


PPE & TPM Requirements listed at each Station

13

• PPE and TPM requirements are listed at every workstation


Visual Gauge markings

14

Gauge Highlighting: Red - failure mode Yellow – warning/execute control plan Green - normal


VISUAL STANDARD

ATTRIBUTES OF VISUALIdentify Pipes at Key Locations OnlyHighlight Processes, not Facilities. Pipe Labels are “Snap-on” Collars: Supplier Grainger item # 6GT35Color Code Based upon ASME A13.1 – 2007 US Piping Identification Standards

15

Pipe LabelingMaterial

Background Color

Legend Letter Color

Background Color and

Letter SampleFire quenching (water, foam, CO2, etc)

Red White LEGEND

Toxic and corrosive Black LEGENDFlammable Yellow Black LEGENDCombustible Brown White LEGENDWater (potable, boiler feed, cooling, etc)

Green WhiteLEGEND

Compressed air Blue White LEGENDDefined by site (for other materials not listed)

Purple WhiteLEGEND

Defined by site (for other materials not listed)

White BlackLEGEND


Gray WhiteLEGEND


Black White LEGEND

NDLEGEND LEGEND

LE

GE

ND

Label at line of sight


5S FOR FLOW

BLUE Work in Process

YELLOW Main Aisles, General Areas, Cart Parking Areas

YELLOW / BLACK Machine Guarding

RED Electrical Shutoffs/ Fire Protection/ Defective Material

GREEN Final WorkStation

ORANGE Moving Crane Parts, Compressed Gas Racks

Visual Factory Guidelines


VISUAL standard

ATTRIBUTES OF VISUALSolid Lines or Corners for Floor Markings

18

Floor Marking

EH&S, Non/Hazardous Waste, Non-conforming material

Incoming/Outgoing Product (Raw or Finished Goods)

WIP in Work Cell

Main Aisle Borders

4” width

2” width

2” width

2” width

2” width

Cart Parking Location

Standard Corners

Floor Tape Specification: High-Strength, Double-Coated Tape, Removable Pressure Sensitive Rubber-Based Adhesive. Source: WWW.Mightyline Store.com

Note: Standard colors for manufacturing areas


Material Presentation for Modular Flow


• Material Presentation Guidelines• Creform Kit Carts• Heavy Part Delivery Carts• Extra Large Parts• Standard Work for Developing Material

Presentation




Presentation



Guidelines

• Forklifts and cranes restrict flow. Eliminate the use of forklifts and cranes for material delivery to the cell and material handling in the cell as much as possible.

• Forklifts should never enter the station. If forklift delivery is required, it should be at the front of the station

• Searching for a part should never happen• No unpacking/opening boxes/searching through containers should

happen at station• No carts over 5 ft, as it will block operator view


Guidelines• Material Presentation is designed in advance not arrange while working • Parts should be presented to technicians similar to a surgeon in an operating room• Material availability should be so ‘transparent’ that a visitor should be able to tell if

all of the parts needed are present• We should be able to easily tell if we have a clean start• Each part should have a dedicated and easily identifiable location and usage • Maximize use of material carts (one person can move without any material

handling devices) where safety is not compromised• Material should be delivered at preset time (pitch). The target time should be half

of a shift with a maximum of one shift.


Guidelines

Are all of the parts available for a clean start?



Presentation



Material Presentation CartsIn order to eliminate the use of cranes and pallets and to provide point of use parts to operator with no unpacking or waste generation as much as possible parts will be presented to the operators on carts.

Two type of carts: Creform cart and Heavy Part Delivery cart

•*Under XX lbs use Creform kit carts•*Over XX lbs use heavy part delivery cart (need name for this cart)*Need to finalize sizes globally


Creform Kit Carts • Modular carts made with Creform• Standard sizes (target 3)

Example:•Small = 2 x 2 x 3’•Medium = 2 x 4 x 4’•Large = 3 x 6 x 5’

*Need to finalize sizes globally


Creform Kit CartsMany options for creform cart configurations


Creform Kit Carts

• Parts shadowed for material presentation

• Designated location for each part

• Missing parts are easily identifiable

Reference sites:• http://plasticeng.com/• http://www.youtube.com/watch?v=r

8A7jPR72o4&feature=youtu.be

http://plasticeng.com/

http://www.youtube.com/watch?v=r8A7jPR72o4&feature=youtu.be

http://www.youtube.com/watch?v=r8A7jPR72o4&feature=youtu.be


Creform Kit Carts

Small PartsStandard method needed for small parts commonly used

• Nuts/Washers => Size specific rods??

• Shafts => PVC tubes?• Bolts => Containers ??

Right quantity must be easily visible



Presentation



Heavy Part Delivery Cart

Heavy parts (>XXlbs or >X’xX’)• Universal base • Heavy duty/stable• Single person can move it• Multiconfigurable for different

parts/projects



After some design work heavy duty universal base accepts custom tops

Update with liftup red top and label 3 parts



After some design work heavy duty universal base accepts custom tops

Configurable top

Universal base

Forklift Guides

Make pic on left like picture on right


Heavy Part Delivery CartReal life example



Heavy Part Delivery Cart can be use for parts like these.



Presentation



Extra Large Parts

Other methods to remove forklifts should be utilized


AirFloat

• Movable air pallets• Air Platform XL can move up

to 150,000 lbs • U pallet can be used for

material presentation • Cost effective XL platform

ranges from 15K to 30K

Air platform XL

U pallet platform

Air Bearing Skid

http://www.airfloat.com/equipment/air-platforms/

http://www.airfloat.com/equipment/air-platforms/



Presentation



Material Presentation Docs• Complete PFEP, Kitting Form, and Station

Design (Pitch) FormSequence Part # Model Part Description

Usage Location

Storage Location

Order Frequency SupplierContainer

Type

Standard Container

Qty.

Quantity per Tree

Weight (kilograms)

X (in.) X Y (in.) Y Z(in.)Shipment

SizeT/T

>P1000091950 DU100145239 EVDT ASSY, 5 1/8 X 2 1/16-15K, 18 3/4 TORUS IV 15K BTM X 18 3/4 H4 TOP, PRODUCTION XT, HESS TUBULAR BELLS

1 93600 (42457) 0.0 0.0 0.0 0.0 0.0

1 >>P1000108956 DU100144443 XT SECONDARY MODULE EVDT ASSY, 5 1/8 X 2 1/16-15K, 18 3/4 TORUS IV 15K BTM X 18 3/4 H4 TOP, PRODUCTION XT, HESS TUBULAR BELLS

1 50225 (22782) 0.0 0.0 0.0 0.0 0.0

2 >>P1000108957 DU100144444 LOWER TREE FRAME SECONDARY MODULE, 5-15K EVDT, PRODUCTION XT, HESS TUBULAR BELLS

1 29496 (13380) 0.0 0.0 0.0 0.0 0.0

3 >>P1000110098 DU100144013 FRAME ASSY, VERTICAL SUPPORT, PROD SIDE, 5-15K EVDT, W/ ANODE

1 358 (163) 10.8 273.1 56.2 1427.0 68.9

4 >>P1000088841 DU100116649 FRAME ASSY, VERTICAL SUPPORT, ANN SIDE, 5-15K EVDT, W/ ANODES

1 628 (285) 15.9 404.1 62.6 1589.0 101.5

5 >>P1000104320 DU100122560 ROV PANEL, ASSY, CIT ON PSDV, F/ 5-15K EVDT

1 62 (29) 15.5 393.7 16.8 426.5 20.7

6 >>P1000090022 DU100113731 GROUP OF PARTS, SET-OUT, F/ ACCUMULATOR SUB-ASSEMBLY F/ 15K EVDT

1 581 (264) 15.9 403.2 24.3 616.3 64.6

7 >>P1000072658 DU100086333 UPPER TREE FRAME WELDMENT, ROOF STRUCTURE, F/ 5-15K EVDT

1 2190 (994) 138.5 3518.0 104.8 2661.0 30.6

Timing (zero to full shift)

Part Number Part description QuantityMaterial Handling Device

(Delivery to Station)Size of Part Number- Special Tooling Needs-

Special Material Handling Needs-

Safety Concerns

Day 1/0 HRS P1000108957 FSM 1 Crane (50 tons)/Slings N/A FSM handling toolP1000096309 U/S FLOWLOOP 1 Forklift/Pallet 49.77X 53.69X 16.50 Off set handling toolP153000 NUTS 12 Kit cart 3.38X 3.19X 1.49P1000048292 STUDS 12 Kit cart 2.1X 2.1X 7.6373-062-169 GASKET 1 Kit cart 6.83X 6.83X 0.62P1000108956 TSM 1 Crane (50 tons)/Slings N/A

6 HRS P1000107431 HVY HEAD SCREW 12 2.7X 2.34X 3.72P137440-0000 WASHER 12 2.4X 2.39X 0.07 2.5P153000 NUTS 24 3.38X 3.19X 1.49P1000048638 STUDS 12 2.02X 11.5X 2.0273-062-169 GASKET 1 Forklift/Pallet 6.83X 6.83X 0.62

12 HRS P1000080183 SPACER SPOOL BODY 1 Forklift/Pallet 0X 0X 0P152164 GASKET 4 Forklift/Pallet 1.68X 1.68X 0.38P1000100723 WELD NECK FLANGE 1 2.17X 8.57X 6.38P1000072699 SPACER 1 3.38X 2.28X 2.28P206197 PAD STUDS 4 NO-DWG78-035-032 NUTS 8 NO-DWGP153495 PAD STUDS 4 NO-DWGP160931 ASV bucket 1 13.97X 18.37X 8.55P136404-0000 PSV bucket 1 13.97X 18.37X 8.55

Pitch # 8

TimeCum. Time

NPT Factor

NPT Adjus

ted Time

NPT Adjus

ted Cumu

l. Time

Technician 1 Technician 2 QA Technician 4 Item #Material Part

NumberDescription Quantity Tooling Required

In station material handling (crane, slings..)

Check for common mistakes (failures) (visual inspection/hands on quality failures)

JSA form

4 >>P1000088841 LEFT SIDE SUPPORT 1 Combo wrench Crane207 >>P1000093498 BOLTS 4 Sockets set Slings225 >>P1000085680 NUTS 4 Hammer231 >>P1000034346 WASHERS 8 Hex key set229 >>P163166 WASHERS 16 Depth mic46 >>P1000104465 ROV EXTENSION ROD 1 Off set handling tool35 >>P1000009878 COUPLER KIT 140 >>P1000009857 SLEEVE KIT 147 >>P1000090277 ROV EXTENSION ROD 134 >>P1000009880 COUPLER KIT 139 >>P1000009855 SLEEVE KIT 1

Extension Rods Hex key setCombo wrenchs

15 >>P1000113381 PROTECTION PLATE 1 Combo wrench Crane208 >>P1000093499 BOLTS 4 Sockets set Slings225 >>P1000085680 NUTS 4 Off set handling tool

75 105Install Sm. Valve Ext.

Rods. (qty5)Install Sm. Valve Ext. Rods. (qty4)

30 135 Install Protection Plate CP Check

Project # Tubular Bells Station # 1 Day # 2 Pitch Time: 6hrs

60 90Install Left Side

Support/ Install ROV Extension Rod to PSV

Install ROV Extension Rod to ASV/ Install ASD

Funnel

Measure depth PSV and ASV

30 30 JSA JSA


Create Creform PrototypeWork with one pitch at a time1.Sort parts by weight/cart type

• Creform cart• Small parts(fasteners, etc..)• Parts under XX lbs

• Heavy parts – over xx lbs• Extra Large parts

2.Collect all available parts3.Where parts are not available obtain a 3-D drawing


Create Creform Prototype

4. Select tray size (from standard list) and cut cardboard to selected sizeIf parts are available:

• Arrange parts on cardboard • Trace parts onto cardboard

If parts are not available:• Obtain an actual size drawing of the part• Cut part out of drawing to make paper

templateCreate several options were possible*Note - Part layouts should follow installation sequence and not cart optimization


Prototype Cart Reviews

• Conduct walk thorough of tasks with prototype cart options

• Determine best cart layout with technicians

• Take pictures and trace finished designs

• Document cart sizes in the Kitting Form


Point of Use Tooling


Point of Use Tooling Hand Tools • All hand tools will be shadowed and will be Point of Use • Mounted on creform at workstation with wheels• Only what is needed will be at each station `


Point of Use Tool Control

• Tools are clearly identified location and tool type with picture make it easy for even a customer to know if something is missing


POU TOOLING IMPLEMENTATION

51

POU Tooling and fixture at employee’s reach. NO TOOLBOXES


Creating tool shadow boards

52

http://plasticeng.com/


VISUAL STANDARD

ATTRIBUTES OF VISUALPOU (Point of Use) Tool LocationTool AccountabilityFOD PreventionClear Color Contrast Between Top and Bottom. (See slide 6 plastic engineering)

53

Tool Shadow Boarding


Tooling Presentation

ATTRIBUTES OF VISUALTool AccountabilityHighlights Tool StatusMissing Tool Replaced With Physical Item Describing Tool StatusFOD Prevention

54Note: Standard is to have tool control method in place


MODULAR FLOW


5 Station Design Colors or Numbers

56


57


Balance Chart

Current State

Future State/ Moveable wall to eliminate crane usage

TUBULAR BELLS FLOW

60 Hours

120 Hours

120 Hours

Day 1 Day 7 Day 28Day14 Day21

Ship

22 Days

Takt Stations

60 Hours

60 Hours

60 Hours

FMC modular flow guidelines 08-03-13

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Transcript of FMC modular flow guidelines 08-03-13