LeanManufacturingWK3精益生产3英文.pptVIP

lean manufacturing training week 3 one-piece flow also known as “single piece flow” ideal state where items are processed and moved directly to the next process one piece at a time each processing step completes its work just before the next process needs the item and the transfer batch is one Takt Time:the heart beat of one-piece flow one-piece flow benefits of one-piece flow: builds in quality creates real flexibility creates higher productivity frees on floor space improves safety improves morale reduces cost of inventory one – piece flow “If some problem occurs in one-piece-flow manufacturing then the whole production line stops. In this sense it is a very bad system of manufacturing. But when production stops everyone is forced to solve the problem immediately. So team members have to think, and through thinking team members grow and become better team members and people.” Teruyuki Minoura, former President, Toyota Motor Manufacturing, North America jidoka Stopping the process to build in quality “A method to detect defects when they occur and automatically stop production so an employee can fix the problem before the defect continues downstream.” Poke Yoke – Error Proofing one – piece flow one – piece flow example: Operation A supplies parts to Operation B, which supplies to Operation C Flow that is not defined one – piece flow one-piece flow one – piece flow establishing one – piece flow define and dedicate the space for one piece – space outlined with tape or paint to show only one piece is permitted and a sign to further clarify this space to be physically limited (controlled) by allowing enough room for a single piece Single piece flow with visually defined agreement leveling leveling leveling leveling by volume case study: demand varies between 800 and 1200 units manufacture at long term average and carry inventory to ensure stability of the production process in this case production would be 1000 units with minimum of 200 inv