TenantsofSinglePieceFlowDoNot

MakeDefectsDoNot

PassAlongDefectsDoNot

AcceptDefectsZeroDefects=0DefectsNot3.4ppmQuality,Quality,Quality…DefectsaretheWorstKindofWaste

7TypesofWaste

DefectivePartsOverProductionInventoryMotionTransportationWaitingManualTouchesBatchSinglePieceFlowFrom:TheToyotaProductionSystemBuildingQualityintotheProcessSinglePieceFlowThenextprocessisthecustomer…neversenddefects!

SampleInspectcatchesDefecttooLateWhenyouFinallyFindaDefectHowmanymoredoyouhave?Wherearetheyintheprocess?WhatistherootCause?

SinglePieceFlowcatchesDefectsimmediatelyWhenyoufindaDefectYouonlyhaveoneYouknowwhereitoccurredYouCanfind/ResolvetheRootCauseimmediatelyCheck,Do,VerifyCheck-Thepreviousoperatorswork.Do-Yourwork.Verify-Thatyoudidyourworkcorrectly.ProcessInspectTransportTransportationisintegratedintotheproductionprocessviaautomatione.g.,movinglineProcessInspectProcessInspectTransportProcessInspectTransportationisintegratedintotheproductionprocessviahumanconveyancee.g.,Chaku-ChakuBuildingQualityintotheProcess2waystoperformSPFThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyGetsyouintoPartsPerMillionquality-Whenyouverifyyourwork,youcatch1flawin100parts.Thenextpersonchecksyourworkandcancatch1/100sothat’s1/10,000.ThenthatpersonVerifiestheirworkandcancatch1/100.That’s1/1,000,000errorsthatcangetthrough.

Check,Do,VerifyEveryCustomerinaProcesshas:-arighttoexpectperfectmaterial-anobligationtoinspectthematerialbeforeuse.-anobligationtoinformthepreviousstepintheprocessofanyproblem.-anobligationtostoptheprocessuntilanyproblemhasbeenresolved.SinglepieceoronepieceflowisameanstoprimarilybuildQualityintotheprocess.ThisisachievedbyestablishingataktTime,developingstdwork,andswip.ThepremiseisthatanOperatorcanonlyworkononepieceatatime,andperformsaQuickqualitycheckontheCTQsoftheprocessbeforemovingTheparttothefollowingprocess.Ifadefectisdetected,JidokaIsenacted…thelineisstopped,andimmediateactionistakenToremediatethesituationandtakecountermeasurestopreventreoccurenceTakttimeStdworkFlow:work(process)thatisdoneinconjunctionwithorsimultaneoustotransportationOnePieceFlow

Theproductionisorganizedintoasynchronouschainwhereeachpersonhasabalancedamountofworkrelativetohis/hersupplierandcustomerinthechain.Asonepersonfinishestheirelement,sodoall.Workisthenmoveddownthelinesynchronously.Everypersonisempoweredtostoptheproductionprocessifarejectisspotted.OrganizationAreaSupervisorNew/RevPageofDateProductionLinePartNumberPartNameOperatorStandardWorkSheetTo:TurnsDPU'sScopeofOperationsFrom:QualityCheckSafetyPrecautionStandardWork-in-Process#LotsofStandardWork-in-ProcessTakt/RateTimeTotalManual&TravelTimeMan/TravelTimeOperatorEndFinishWeldEndFinishWeldOrbitalWeldHydroTestMarkMech.CleanTorchBrazeTubingCFMCellFernBissonnetteCell6AllPartsAllTubes11Mech.CleanRawmaterialWeld100/DayFPIX-RayEDM2ndQtr.‘01EndFinishOutsideCell27-avglot=6FlexFinishedGoodsACTIONWORKOUTgGEMSGlobalProductionSystemThenextprocessisthecustomer…neversenddefects!Check,Do,VerifyOnePieceFlow

Yourcustomeristhenextstepintheprocess.Givetoyourcustomer,exactlywhattheyneed(1item),exactlywhentheyneedit,doneperfecteverytime.Tenantsof1pcsFlowDoNotMakeDefectsDoNotPassAlongDefectsDoNotAcceptDefectQuality,Quality,Quality…DefectsaretheWorstKindofWasteSystemofmanufacturinginwhichthefinalprocesswithdrawsthepartsitneedsfromtheprecedingprocessatexacttimingintervals,intheexactstandardizedamountneeded.PullProductionMethodology&SequenceDefinitionRefMaterialPresentationtrainingforexplanationonSupermarketdefinitionandusePartssemblyLineCellorChaku-ChakulineSupplierMaterialInformationSupermarketEmptycontainerFullcontainerLegend1Sequence/TimingPullProductionMethodology&SequenceJITJidokaeGPSforGPCHeijunkaLevelLoadingSequencingFindingabalancebetweenthevolumeofworkthatyourorganizationneedstodoandyourcapacityAdjustingaproductionscheduletomeetunexpectedchangesincustomerdemandOrderingtheproductioninsuchafashiontoachievethedesiredTAKTforallitemstakenfrommemoryJoggerLeveledproductionmeansloweringthepeaksamongthedailyproductionvolumesasmuchaspossibleandmakingtheproductionflowsmoothandunflucuating.Ingeneral,themorefluctuationsyouintheproductionflow,themoremudayouenduphaving.Thatisbecausethecapacityandcapabilityofalinetendstobesetatalevelthatmeetsthepeakproductiondemandratherthantheaveragedemand.Iftheproductionlineproducesonlyasingleproduct,youmaybeabletoreducemudasimplybyadjustingtheproductionscheduleandstaffinglevel.Butifyouwanttoproduceconsistentlyatanaveragelevelwhereyouhavemanydifferentkindsofproductstoproduceinasingleline,youhavetodotheaveragingnotjustinvolumebutinkindsaswell.ThiswayofaveragingbothvolumeandinkindsiscalledproductionlevelingorheijunkainJapanese.LeveledProductionAmountofproductsthatcanbesoldHEIJUNKAAveragebytotalvolumeAverageby

modelLeveledLoadProductionBuildtoforecastBuildtoFGinvBuildafterorderisreceivedALLcomponentsneedtobestockedinRMAnorderfromtheseproductstakesprecedenceover1-2-3products……buildthisfirst!UseStocksBuildStocksTAKT%F1F1F1F1F1F1F2F2F2F2F2F2TAKTTimeDeterminedbyPSI2Q3Q4QOktoBuildtoFGRepeatableProductsNon-RepeatableProductsNeedtoDetermine...HowMuch20bulbsperdayWhatKind15/60Watts5/100WattsWhen5-60W,2––100W,5––60W,2–200W,5–60W,1––100WTAKTLevelLoadMixLevelLoadSequenceIfweweremakinglightbulbs...QuarterlyWeeklyWeeklyFrequency606060606010010060606060601001006060606060100TaktTime=OperatingtimeperdayProductionrequirementperdayAssumptions:MachineBreakdown=0hourSetupChange=0hourDefectRate=0%TaktTimeEquationFormoreinformationonTAKT–RefertoJITSectionQuickExampleSettingtheproductionsequenceofmultipleTRAM––RACTypes(MedSystemsProduct)ProductMonthly

RequirementDaily

RequirementTAKTTimeModel1720units24units5minModel2360units12units10minModel3360units12units10minTotal1440units48units7.5minThisisdatafor3products,Model1,Model2,andModel3,areproducedatGEMS.Thechartdisplaysthemonthlyproductionlevel,thedailyproductionlevel(monthlydividedby30),andtheTakttimeforeachproducttype.THEYAREALLPRODUCEDONTHESAMELINE.Howcantheseunitsbebuiltinalevelproductionmodeusingthisexample?Model1Model2Model3DetailedExampleSincethesethreeproductsareonthesameline,youwillneedtofollowthesequencepatternof1-2-1-3inyourproductionmix.Bydoingitthiswayyouareabletolevel-loadyourproductionbothintermsofquantityandtypes.#1––Prod1#4––Prod3#2––Prod2#3––Prod1REPEATMixedAssemblyLineProductionSequencebyTypeIfproducedinbatches,onlytheModel1’swillmeetTakttimesIfproducedtoasequence,2unitswillbeproducedin2TakttimesLet’’sshowhowwevalidatethis…ModelLineTaktTakt/CycleGraphPart-QuantityPartRouter13SeeStdWorkComboSheetforexample.OnesheetiscreatedforeachoperatorSCT=25SCT=40SCT=30766676138127.597.5TaktBuildTime=#ofOperations*TaktActualBuildTime=SCT130230330125240330ModelTBTModelABT1-52+1030ModelObjectives:ProducetoTaktTime(understandingno2productswillhavetheexactsameABT)ThesumoftheDTotiszeroEveryproductisproduceatleastonceNoproductisproducedtwiceinarowCreateaproductsequencewhere:Dtot=S(#ofUnitsinsequence*D)Dtot=-5(#of1’s)+10(#of2’’s)+0(#of3’’s)0=-5(2)+10(1)+0(1)IneachsequencewillcontainoneModel1,twoModel2s,and1Model3)Accordingtotherulesthesequencemustrun:Model1––Model2–Model1––Model3GuidingPrinciples:GPSLevel-loadingPurpose:Toprovideguidelinesfordevelopingthemethodandtoolstolevel-scheduletheshopfloor.KeyElementsofLevel-schedulingProductionunitsarestratifiedaccordingtoplannedsalesvolumeTheproductionsequencecombinesbothordersandforecastSequenceisdesignedtoachievethecombinedTAKTtimeforallitemsEliminatingproductionratevarianceisrequiredtoachieveTAKTtimeOnlybuildhighvolumeproducts(top80%)toFGinventory,ifordersarenotavailableFGinventorylevelsareNOTtargeted,butaresultofTAKTtime&ordersflowLower-levelgroupitemsareNOTsequencedwithoutfirmordersHoldRMcomponentsinventoryonlyforlowvolumeitems.Theseareitemsthatyoucan’tbuilduntilyouhaveanorderFillordersfirstfromFG,secondWIP,&thirdsequencethem(attachtheordertotheproductionplan)9、靜夜四無(wú)鄰鄰，荒居舊業(yè)業(yè)貧。。12月-2212月-22Thursday,December29,202210、雨中黃葉葉樹(shù)，燈下下白頭人。。。19:42:0119:42:0119:4212/29/20227:42:01PM11、以我獨(dú)獨(dú)沈久，，愧君相相見(jiàn)頻。。。12月-2219:42:0119:42Dec-2229-Dec-2212、故人江海海別，幾度度隔山川。。。19:42:0119:42:0119:42Thursday,December29,202213、乍乍見(jiàn)見(jiàn)翻翻疑疑夢(mèng)夢(mèng)，，相相悲悲各各問(wèn)問(wèn)年年。。。。12月月-2212月月-2219:42:0119:42:01December29,202214、他鄉(xiāng)生生白發(fā)，，舊國(guó)見(jiàn)見(jiàn)青山。。。29十十二月20227:42:01下午午19:42:0112月-2215、比不不了得得就不不比，，得不不到的的就不不要。。。。十二月月227:42下下午午12月月-2219:42December29,202216、行行動(dòng)動(dòng)出出成成果果，，工工作作出出財(cái)財(cái)富富。。。。2022/12/2919:42:0119:42:0129December202217、做前，，能夠環(huán)環(huán)視四周周；做時(shí)時(shí)，你只只能或者者最好沿沿著以腳腳為起點(diǎn)點(diǎn)的射線線向前。。。7:42:01下午午7:42下午午19:42:0112月-229、沒(méi)有失敗，，只有暫時(shí)停停止成功！。。12月-2212月-22Thursday,December29,202210、很多事情情努力了未未必有結(jié)果果，但是不不努力卻什什么改變也也沒(méi)有。。。19:42:0219:42:0219:4212/29/20227:42:02PM11、成功就就是日復(fù)復(fù)一日那那一點(diǎn)點(diǎn)點(diǎn)小小努努力的積積累。。。12月-2219:42:0219:42Dec-2229-Dec-2212、世間成事，，不求其絕對(duì)對(duì)圓滿，留一一份不足，可可得無(wú)限完美美。。19:42:0219:42:0219:42Thursday,December29,202213、不知香香積寺，，數(shù)里入入云峰。。。12月-2212月-2219:42:0219:42:02December29,202214、意志志堅(jiān)強(qiáng)強(qiáng)的人人能把把世界界放在在手中中像泥泥塊一一樣任任意揉揉捏。。29十十二二月20227:42:02下下午19:42:0212月月-22