Alain Prioul

Flexibility / Adaptability

Definitions

Flexibility

Ability to quickly change from one part number to another one

Adaptability

Ability to follow customer demand at different Takt Time

Flexibility

Flexibility : Why ?

To reduce WIP + surface + handling + CAPEX

Key condition for high TRS Key condition for levelling

To reduce lead time

Reduce inventories
Q Stock level A

Average stock Safety stock Production (batch size 12h) Q 12 h t

A
t
5

Reduce inventories
Q
Stock level A

Safety stock Production (batch size 2h)

12 h

Average stock

Q
A B C A B C A B C A B C A B C A B C A B C A B C

t
6

Reduce inventories
Q
Stock level A

Safety stock

Average stock

Production (batch size 2h)

12 h

Q
A B C A B C A B C A B C A B C A B C A B C A B C

t
7

TRS Increase
P1
100%

P2 5h

P3

P4

P(x)

5h
75%

5h

1h B 9h 18h A 9h C E G D F H

TRS Increase
P1 5h 5h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
10

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 5h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
11

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
12

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
13

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
14

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
15

P2

P3

P4

P5

P6

9h

x2

TRS Increase
P1 5h 2h 2h 2h 2h 2h 2h 2h 9h 2h 2h 2h 2h
x9
16

P2

P3

P4

P5

P6

9h

x2

Flexibility : Why ?

To reduce WIP + surface + handling + CAPEX Key condition for high TRS Key condition for levelling To reduce lead time

17

Levelling
Ideal condition: Producing all products in parallel at TAKT TIME

(rhythm of customer demand of each part number)

Target : respect the TAKT TIME & full loading of the equipment: Producing all products in small batches close to TAKT TIME

18

Lead Time reduction

Customer demand

Production = Large batches

Lead time

Production = small batches

Lead time

19

Adaptability : Flexible Manpower Line

20

Flexible Man Power Line : why ?

Work Content Number of Operators = Takt Time Work Content change
Result of Kaizen action Work content mix

Takt Time change

Customer demand change n => n - 1

21

Flexible Man Power Line : Definition

Flexible Manpower Line A line which is designed in such a way that productivity is the same, whatever is the

number of operators.
Flexible Manpower System Optimizing labour productivity factory-wide by moving people from one flexible manpower line

to another.
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Flexible man power line : Layout

Unflexible man power line

U cell

Linear (fixe)

23

Flexible Manpower Line : Fundamentals

Linear line configuration or U shape line
Line

No barrier to operator movement

Operators work inside the cell

Operator

Operator loaded to takt time Operation start and finish at the same point One piece product flow by hand
Standard in process stock Multi-process handling Several Standard Work for varying demand Flexible working hours
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Process

Flexible Manpower Line : Iso-productivity !

6 operators

PPH is constant

25

Flexible Manpower Line

Flexible Manpower Line
- avoid overproduction => less WIP , space , handling
- smooth production => better usage of capacity - smooth material flow => control lead time - create standard conditions - make kaizen possible
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