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L THM Hi THT Lean - The Machine That Changed The World Changed The World
L THM Hi THT Lean - The Machine That Changed The World Changed The World
L Th MMachine
hi That
Th t
Changed the World
HIGH
JUMBLED LEAN
FLEXIBILITY
FLOW PRODUCTION
(JOB SHOP) HIGH
COST (LOW COST
LOW AT ANY C
DISCONNECTED VOLUME VOLUME) O
LINE FLOW
(BATCH)
S
T
S
CONNECTED
LINE FLOW
(ASSEMBLY) LOW
FLEXIBILITY
LOW
CONTINUOUS COST
FLOW HIG
VOLUME
RIGHT RIGHT
RIGHT THINGS THINGS
THINGS DONE DONE
WRONG RIGHT
WRONG WRONG
WRONG THINGS THINGS
THINGS DONE DONE
WRONG RIGHT
DONE DONE
WRONG RIGHT
Production Technology Inc. 11/12/97 14
LEAN DESIGN ELEMENTS
) Integrated Product/Process Development
– Multifunctional
M ltif ti l Teams
T
– Well-Defined Development Processes
– D i for
Design f Manufacturing
M f t i & Assembly
A bl
– Supplier Participation
– Cycle Times Reduced
Cycle-Times
– Funding Profiles Changes
– More Designs for the same Development Budget
) Prototypes with Production Processes & Workers
) Production Experienced Design Teams
TIME
Production Technology Inc. 11/12/97 19
KOLBE CONCEPT
) Individuals have three mental faculties:
- Cognitive (intellectual) controls thought
- Affective (emotional) controls feelings
- Conative (functional) controls actions
) The conative faculty translates instinct into acts & deeds
) Individuals have four instincts:
- Instinct to Probe
- Instinct to Pattern
- Instinct to Innovate
- Instinct to Demonstrate
) The Power of the Will propels people to act on their
creative instincts
Production Technology Inc. 11/12/97 20
KOLBE
BALANCED TEAMS
) Increase team productivity by identifying and harnessing an
i di id l’ natural
individual’s t l striving
t i i pattern
tt
– the instinct to Probe deals with detail, complexity and provides
the perspective of experience, FACT FINDER Mode
– the instinct to Pattern deals with structure, order, and provides
focus and continuity, FOLLOW THRU Mode
– the instinct to Innovate deals with originality,
originality risk-taking
risk-taking, and
provides intuition & a sense of vision, QUICK START Mode
– the instinct to Demonstrate deals with physical space and the
ability
bilit to
t operatet manually,
ll andd provides
id durability
d bilit and
d a sense
of the tangible, IMPLEMENTOR Mode
) GOAL: Put the right
g p people
p into the right
g jjobs,, balance the
team
Production Technology Inc. 11/12/97 21
EC Continuum
Outsourcing Virtual
Over The NII Enterprises
Product/Process
Data Driven
Manufacturing
Distributed
Collaborati e
Collaborative
Engineering
Technical
Data
Interchange
Integration of
EDI & Network Enabled
I
Internall Systems
S
Business Practices
Electronic
Data
I t h
Interchange
Subsystem Requirement
Keys = Readability
Clock
& Accuracy
A
Power Display
Manufacturing Requirements
Supply Assembly
• Hardware Requirements
Voltage is Key -- MIL-SPEC Diode
Photo LCD Panel -- Good Solder Joints
Diode Lamp • Process Requirements
-- MIL-STD 2000
-- Wave Solder
ld Machine
hi
• Verification Requirements
-- DOE to Identify Key Characteristics
-- SPC to control key process factors
Best of the Breed in some areas Clearly above the standard in most areas
A sound & systematic approach to all requirements Best throughout the ECRC system
Best of Very strong fact-based improvement process with excellent Current performance is excellent in most areas
Breed analysis Excellent improvement trends or sustained excellence in
Approach is fully deployed with no (even minor) gaps most areas
Strong evidence of benchmark leadership in most areas
Production Technology Inc. 11/12/97 27
PRODUCIBILITY
)A design accomplishment resulting from
a coordinated effort by all engineering
functions to create a functional hardware
design that optimizes ease and economy
of fabrication
fabrication, assembly
assembly, inspection
inspection, test,
test
and acceptance without sacrificing
desired function,
function performance,
performance or
quality.
Taguchi - 50%
QFD FTA/RFTA - 35% SPC
FMEA - 15%
WORKING
GROUP
A Development Process
B Factory Operations
C S
Supplier
i relations
i
Human Resources
D
Policy and External Environment
E
Focus
Workshops
Group
Research Projects
R
Research
hTTeams
Research Reports TIME