Loubser de Kock_16 TOCPA_April 2015_South Africa
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Transcript of Loubser de Kock_16 TOCPA_April 2015_South Africa
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
April 23, 2015 Johannesburg, South Africa
16th International Conference of the
TOC Practitioners Alliance - TOCPAwww.tocpractice.com
DBR Implementation in Long
Touch Time environment
Loubser de Kock, SABN, South Africa23rd April, 2015
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Loubser de Kock
Born 1965, Stellenbosch, South AfricaMatriculated at DF Malherbe High School, PortElizabeth, in 1983.Graduated with a B. Eng - Electronic Engineering atUniversity of Pretoria, 1988.Software Engineer at Denel Land Systems (LIW)(1988-1996); Saab Grintek Defence (1996 2013);SABN (2013 - )My TOC journey began in 2001 when I did a ProjectManagement Course at University of Pretoria (CE-UP)where I met Philip Viljoen.We met again in 2005 when we implemented CCPM ona very challenging project which we recoveredsuccessfully.I also had the privilege of meeting Eli Goldratt at one ofhis Viable Visions Seminars at Emperors Palace,Kempton Park in 2006.
Contact info:Mobile +27 82 82345743Email [email protected]
Loubser de Kock
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Disclaimer
The views expressed herein are those of the
author and do not reflect the official views of the
SARB Group
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Mission:The SABN is the preferred supplier of banknotes to the South African Reserve Bank and other selected Central
Banks.
Vision:We are an innovative solutions partner for the high
security printing industry.
South African Bank Note
Company (RF) (Pty) Ltd
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Overview
Mandela Note Security Features
Security Printing Background
Steps in Identifying the Constraint
Subordination actions Constraint Support
Production Buffer Management System
Preventative Maintenance Prioritisation System
Delivery Fever Chart (Month, Quarter, Annual)
Challenges
POOGI
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Bank Note Security Features
Feel of the Note Overall crisp feel, substrate, snap
1. Watermark Mandela Face
2. See-Through Perfect Print Registration
3. Micro-Printing - Denomination Numeral in the Animal
4. Unique Numbering Increasing Font Size
5. Raised Printing - Coat of Arms, Words Reserve Bank
6. Raised Printing - Blind People,
7. Security Thread Changes Colour, Embedded in the Note
8. Colour Changing Ink
9. Hidden Image HorisontalNumeral bottom left of animal
10. Little Dots/Circles
1010
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Security Printing Background
Duration to print one Bank Note is 28 days.
Plant is running 1-2 shifts, 5 days a week (16/5)
Production Time Analysis: Total Curing Time of 19 days (Ink to dry before next
process)
Total Machine Touch Time < 1 second
Total Operator Handling 9 days (inclusive - counting, moving, QA, weekend)
Production Ramp-up time - 1 month
Order execution time (1 11 mo).
Security Inks and Substrate long lead times ( 4 - 9 mo)
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Identify the Constraint
Check where work was piling up.
At the last step - sorting and packing.
Calculated the theoretical throughput of the line.
Confirmed we had a Balanced Line
Some Curing Stages had a Physical Constraint
Limited Vault size.
Operator inertia and efficiency was not considered a constraint.
These had to be fixed through improvement programs
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Production Plant Design
Highly Configurable depending on demand!
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Subordination actions
Implemented Symphony on the Stores Supply Chain to ensure reliable availability(Previous Presentation)
Implemented a Kanban system at the constraint
Consumables
Machine Spares
Dedicated Maintenance Crew for Breakdowns
Backup Electricity Supply only for the constraint
Implemented a Drum Buffer Rope system
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Production Capacity Analysis
19 days19 days 7 days7 days
2days2days
RAW MATERIAL
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Buffer Management System
Calculated the buffer limits (BL = RRLT x MC x 1.5)
Choke the Release to control the volume of WIP in the system
Based on orders created a daily demand to drive production daily targets for orders in hand.
Phase denominations in/out as part of the overall buffer. Denomination composition of buffer.
Progressive Priorities per Production Process based on Buffer Level
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16th International Conference of the TOC Practitioners Alliance - TOCPA
www.tocpractice.com
Buffer Status Dashboard
01 April 2014 to 30 March 2015 WORK IN BUFFER STATUS
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N1 40.9 59.6 5.9 3.6 25.9 5.9 9.1
N2 0.0 0.4 0.2 0.2 14.8
N5 35.9 52.6 5.0 6.3 9.4 8.0 12.6 2.2 3.6 4.5 2.3 3.6 3.2 1.4 12.6 1.4 11.3 -0.7
P10 17.1 0.0 0.0 0.0 29.2 -5.4
P20 8.3 33.5 5.0 9.0 7.6 0.4 0.2 2.4
TOTAL 85.1 162.8 15.8 19.3 42.9 13.9 22.1 2.5 3.6 4.5 2.3 3.6 3.2 0.2 12.6 1.4 0.2 57.7 -6.1
% BUFFER PENETRATION100%