Professional Documents
Culture Documents
MIXED-MODEL
LINE DESIGN
LEANROADMAP ®
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® GETTING STARTED
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® MIXED MODEL LINE DESIGN(1.0)
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN ASSESSMENT & MASTER PLAN (1.1)
If decision is to engage
Conduct a Lean-focused
Lean consultants, screen
assessment of Target Area,
1.1.3 for track record, deep
including financial and
SELECT LEAN experience, compatibility.
operating data, key
CONSULTING FIRM Must be headed by a C-
metrics, and pre-Lean YES
benchmarks. Level Champion, and
directed by a Team Leader
1.1.2 skilled in Lean principles
1.1.1 DECIDE: USE 1.1.4 and methods.
START ASSESSMENT
COMPLETE SELF- OUTSIDE LEAN NO APPOINT LEAN TEAM
AND MASTER PLAN
ASSESSMENT TOOL CONSULTANTS LEADERSHIP
?
LEAN STEP-BY-STEP SERIES
Write Master Plan for Line Design. For opportunities in Future Draw Current State Value
State VSM, quantify Apply Lean Thinking for As team, walk the Gemba
Include tasks and schedule, cost- improvements to Current Stream Map. Analyze
benefits: lower inventory and sequence of processes.
benefit analysis, paybacks, State Map. Draw Future Value-Added vs. non-VA
costs, new floor space for Observe with “Lean eyes”:
assigned responsibilities. Obtain State VSM showing these time, distances,
growth, incremental sales problems, opportunities,
top management sign-off and improvements. disconnected processes.
from short cycle times, etc. waste, handoffs, confusion.
ownership. Record process times.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN: DATA GATHERING (1.2)
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN: DEVELOP STANDARD WORK (1.3)
along with operators, engineering to be able to review the steps carefully. staff workers, and review with 1.3.6
and Kaizen Leader guidance. them. Agree on the optimum AUDIT & STANDARDIZE
sequence of step, especially when WORK STEPS
there are differences.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN: RESOURCE CALCULATIONS (1.4)
TOOL LIST
RESOURCE
1.4.7 1.4.6 1.4.5
CALCULATIONS
REFINE & REVIEW CALCULATE PREPARE STANDARD
COMPLETE
RESOURCE CALCS RESOURCES TIME MATRIX
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN: WORKSTATION DEFINITION (1.5)
1.5.2 1.5.3
START WORKSTATION DEFINE MACHINES DEFINE LABOR
DEFINITION PROCESS IN PARALLEL SEQUENTIALLY
LEAN STEP-BY-STEP SERIES
TOOL LIST
WORKSTATION
1.5.7 1.5.6 1.5.5
DEFINITION
TRAIN AND CERTIFY CREATE DETAIL DESIGN OF
COMPLETE
OPERATORS GWIs WORKSTATIONS
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN CONCEPTUAL LAYOUT (1.6)
Gather and review all work Schedule ample time for Referring to the Process Flow
to-date. Revisit the Conceptual Line Design session. Matrix, with volumes, define the
Present and Future State Lay out work area, or wall space sequence of processes carrying the
Value Stream Maps and with butcher paper. Provide highest unit volume. Lay out this
improvement areas. pens and colored sticky notes. path with sticky notes.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN CAD LAYOUT (1.7)
With all details complete and With detailed Layout Plan, With processes located, add
confirmed, prepare final walk the facility, verifying detail for aisles, storage, crane
documents for Layout Plan: locations, equipment sizes, reach and load, electrical, ceiling
CAD print-outs in large scale, utilities, clearances, and clearances. Call in Engineering
or blueprints. Copy, post and other issues. Include and Maintenance for review.
distribute as required. Engineering, Maintenance. Document thoroughly on CAD or
paper layout sheets.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN: DEPLOYMENT PLAN (1.8)
Gather Layout Plan Create list and capital budget for all
With Maintenance and Engineering,
documents, resource new equipment. Set specifications,
determine all work required on
calculations, and lists of capacity, footprint, investment.
facility: utilities, remodeling,
production equipment, Obtain Management approval, and
moving racks, HVAC. Decide on in‐
fixtures, and other assets issue POs and contracts to meet
house labor or contractors.
q y g
required by Line Design. time lines.
Working with full team, determine 1.8.4
long lead‐time tasks, critical path, SET DEPLOYMENT
and preferred sequence for moves SEQUENCING
and installation of equipment.
With action items and sequences 1.8.5
set, build project management BUILD PROJECT MGMT
spreadsheet or GANTT chart. SPREADSHEET
R
Recommended to use PM
d d PM
software.
For all Capital and Expense
Deployment of Layout and With project management spreadsheet
outlays not already approved,
Move is ready for launch. loaded, determine required milestones
obtain Management sign‐off and
and dates Assign responsible people
and dates. Assign responsible people.
issue POs and contracts.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide. Version 2.0.
LEANROADMAP® LINE DESIGN CONDUCT TRAINING (1.9)
TOOL LIST
Conduct “Lean Overview” training for 1.9.4
1.8.3 Certification Board (example) all operators and supervisors. CONDUCT “LEAN
Emphasize benefits of the Lean OVERVIEW” TRAINING
workplace. Hands-on and role-
1.8.4 “Lean for Operators” Training
playing for flexing, IPKs, Kanban bins.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN LEAN PROCESS LIVE (1.10)
PLAN COMPLETE
Communicate plans
thoroughly, emphasizing 1.10.5
value of Lean project. COMMUNICATE AND
Anticipate and address BUILD BUY-IN
operators’ concerns.
TOOL LIST
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN KAIZEN LINE PERFORMANCE (1.11)
improvements. Monitor,
Calculate investment in adjust and fine-tune the
new process machinery. Lean Line’s balance, flow
1.11.3-C May be required by and throughput.
ADD process variability or
RESOURCES capacity needs.
1.11.1 1.11.2 1.11.4
EVALUATE LINE APPLY LINE BALANCING IMPLEMENT
BALANCE TOOLS Calculate IPKs, and use when KAIZEN TOOLS
1.11.3.D actual times vary around
INSTALL IN-PROCESS Takt. A few inventory units
Look for indicators of line KANBANS (IPKs) can significantly smooth flow.
For each instance of line
imbalance: WIP piling up, imbalance, analyze causes, and
bottlenecks, constraints, apply one or more appropriate
idle operators, poor line balancing tools. Calculate inventory required. Can
volume and throughput. 1.11.3.E be used when average work time
ADD INVENTORY exceeds Takt. Build inventory
AND/OR TIME up- or down-stream, plus
additional work time.
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.
LEANROADMAP® LINE DESIGN LEAN AUDIT & CERTIFICATION (1.12)
The LeanRoadMap® is a registered trademark of Leonardo Group Americas, LLC (http://www.leonardogroupamericas.com) © 2013 All rights reserved worldwide.