Working Time Synchronization

Purpose of Working Time Synchronization

Purpose of the element is the ability of the value stream to follow the customer tact
in needed shift system flexibility for the planned production period.
The continuous flow of entire value stream by synchronization of value stream
sections and indirect support areas minimizes needed stocks and total
replenishment lead time.

Aspects of the question are:

 Synchronization of value stream sections

 Synchronization of value stream functions

 Adaption of shift model for planned period

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 Working Time Synchronization

Definition RB

Source Make Deliver

Focused area

Synchronization of Synchronization of Planning of Shift

value stream functions value stream sections Models
Condition

OXOX

Pre-Assy,
Machining Assy Staging
…

EZRS EZFE EZ

Losses
KPI

Defined Stocks
Indirect productivity

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 Working Time Synchronization – Level 1

Concept Synchronization of
value stream functions:
OXOX

Production Pacemaker

Internal logistics
Service (Maintenance, incl. MAZE stocks
Quality (e.g. test labs, incoming inspection) TEF Bosch
comes per demand
Flow related indirect processes
Shipping employees are available in all production shifts
Receiving employees are available in all production shifts

KPI Losses: Is measured

Time for release
of blocked parts

Is measured
Reaction time of
repair service

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 Working Time Synchronization – Level 2

Concept Synchronization of
value stream functions:
OXOX

Production Pacemaker

Internal logistics
Service (Maintenance, incl. MAZE stocks
Quality (e.g. test labs, incoming inspection) TEF Bosch
comes per demand
Flow related indirect processes
Shipping employees are available in all production shifts
Receiving employees are available in all production shifts

Shift model for planned period: Adaptation with every leveling period to follow
customer takt

KPI Losses: Defined stocks: 140

• Time for release of blocked parts OXOX
120
• Reaction time of repair service 100
Re
80
LO
60 Wi
02.14 – 08.14 – 02.15 – 08., 09, … 40 Sa1
07.14 01.15 07.15
to cover fluctuation of shift Sa2
2014 2015
20
differences (is planned for
• Average of last 2 rolling half years show positive trend Pacemaker loop) 0
or Month Month Month Month Month Month
• stable on target level of business requirements 1 2 3 4 5 6

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 Working Time Synchronization – Level 3

Concept Synchronization of Synchronization of value

value stream functions: stream sections:
OXOX

Receiving Make Shipping

Production Pacemaker OXOX

+ Pacemaker
Internal logistics
Service (Maintenance, incl. MAZE stocks
Quality (e.g. test labs, incoming inspection) Mo-Fr. 1 Shifts 3 Shifts 3 Shifts 1 Shifts
Flow related indirect processes Weekend 1 Shifts 3 Shifts 3 Shifts 1 Shifts
Shipping employees are available in all production shifts
(Example)
Receiving employees are available in all production shifts

Shift model for planned period: Adaptation with every leveling period to follow
customer takt

KPI Losses: Defined stocks:

OXOX

• Time for release of blocked parts

• Reaction time of repair service 02.14 –
07.14
08.14 –
01.15
02.15 –
07.15
08., 09, …

2014 2015

to cover fluctuation of shift • Average of last 2 rolling half years show positive
differences (if impact exists) trend or
(e.g. Kanban Formula Re + LO) • stable on target level of business requirements
02.14 - 05.14 - 08.14 – 11.14 - 02.15 - 05.15 - 08. - 10.11. - 12.
04.14 07.14 10.14 01.15 04.15 07.15
2014 2015
Indirect productivity:
• Average of last 6 rolling quarters show positive trend • Average of last 2 rolling half years
(stagnation of single quarters acceptable) show positive trend or
or • stable on target level of business 02.14 –
07.14
08.14 –
01.15
02.15 –
07.15
08., 09, …

• stable on target level of business requirements requirements 2014 2015

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 Working Time Synchronization – Level 4

Concept Synchronization of Synchronization of value

value stream functions: stream sections:
OXOX

Receiving Make Shipping

Production Pacemaker OXOX

+ Pacemaker
Internal logistics
Service (Maintenance, incl. MAZE stocks
Quality (e.g. test labs, incoming inspection) Mo-Fr. 3 Shifts 3 Shifts 3 Shifts 3 Shifts
Flow related indirect processes Weekend 3 Shifts 3 Shifts 3 Shifts 3 Shifts
Shipping employees are available in all production shifts
(Example)
Receiving employees are available in all production shifts

Shift model for planned period: Adaptation daily according to synchronized

customer requrement

KPI Losses: Defined stocks:

OXOX

• Time for release of blocked parts

• Reaction time of repair service
02.14 - 05.14 - 08.14 – 11.14 - 02.15 - 05.15 - 08. - 10.11. - 12.
04.14 07.14 10.14 01.15 04.15 07.15
2014 2015

02.14 - 05.14 - 08.14 – 11.14 - 02.15 - 05.15 - 08. - 10.11. - 12.
04.14 07.14 10.14 01.15 04.15 07.15
2014
• Average of last 6 rolling quarters show positive trend
(stagnation of single quarters acceptable)
or
• stable on target level of business requirements
to cover fluctuation of shift • Average of last 6 rolling quarters show positive trend
differences (if impact exists) (stagnation of single quarters acceptable) or
(e.g. Kanban Formula Re + LO) • stable on target level of business requirements
2015
Indirect productivity:
• Average of last 6 rolling quarters show positive trend
(stagnation of single quarters acceptable) or
• stable on target level of business requirements
02.14 - 05.14 - 08.14 – 11.14 - 02.15 - 05.15 - 08. -
04.14 07.14 10.14 01.15 04.15 07.15 10.
11. -
12.
2014 2015

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Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.