Demand Flow

Planning For Implementation

Designing a Flow Manufacturing
Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation

Step 1: Value Stream Map

 Understand the product flow / manufacturing sequences

 This step is accomplished by developing a Value Stream Map
 Look at the products as PROCESSES
 Output of one process is consumed by the next process
 Start from the point closest to the customer and work backward
 Start from final assembly and move backward into sub-assemblies and to the
start of the process

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Current State Map Planning For Implementation

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Future State Map Planning For Implementation

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 Planning For Implementation
Designing a Flow Manufacturing
Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation

Step 2: Sequence of Operations

SEQ. Description of Step V.A. Set Set Machine Labor Material Labor TQC
No. Task (Y) / Up Up Run Time Move Move Information
(N) (M) (L) Time
10 Connect lower power Y 0.3 Verify placement and
drive coax cable to connection
lower logic chassis
coax connector
20 Install Disk drive onto Y 0.5 Verify position and
the cabinet orientation
30 Move to Finished N 0.4
Goods inventory
40 Wait for Material to N 0.5
arrive at the work
station
50 Set up the test station N 0.45
60 Run system test N 0.3 Entire system must be
tested for 15 seconds
70 Power down system Y 0.1

80 Test work station N 0.65 All Parameters must

be pass

Sequence of Operations Sample Form

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 Planning For Implementation
Designing a Flow Manufacturing
Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation

Step 3: TAKT Time Calculation

Matches the pace

of production Total “available” production time
to the pace of sales TAKT time =
Customer Demand

Example

Production time available = 460 min

1 minute

Customer demand = 460 pieces

1 minute
1 minute

TAKT time = 1 minute/piece

1 minute 1 minute

Takt time

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 Planning For Implementation

TAKT/Cycle/Lead Time Comparison

TAKT Time: How often we need to produce to meet customer demand without
overproducing

Operation Cycle Time: Total Time for one operator/resource to complete their operation

Lead Time: Total Time to produce one product from the first operation to the last
operation including delays. Delays may be due to unbalanced lines, high WIP,
batching processes, between operations.

TAKT Time: 95 sec. (every 95 sec. a customer withdraws a part)

95s TAKT Time
90s OPN CYCLE Time: Op #1 = 95s, Op2 = 85s, Op3=90s etc
85s
LEAD Time: Example - if we start a product at Op #1 at “time
zero”, Lead time is the cycle times of each operation PLUS
the delay/batch time in between each operation
1 2 3 4 5
Operation’s Cycle time

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 Planning For Implementation

Designing a Flow Manufacturing

Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation

70
Step 4: Balancing the Flow of Work

60

Takt
50
Time
TIME

40

30

20

10

0
10
A 20
B 30
C 40
D
OPERATIONS

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 Planning For Implementation

Step 4: Balancing the Flow of Work

Four Steps For Balancing Operations

Based on Takt Time

1. Break Operations into Job elements

2. Identify and Remove Waste from operations

3. Define Improved job elements

4. Re-balance job elements by combining tasks

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 Paper Kaizen

Stacked Cycle Times of Process Elements

Current Improved
125 Im 125
120 pr 120
ov
115 em 115
110 en 110
t in
105 Pr 105
100 oc 100
es
95 sL 95
90 T 90
85 Waste 85
80 80
75 75
70 70
65 65
60 Waste 60
55 55
50 50
45 45
40 40
35 35
30 30
25 25
20 Waste 20
15 15
10 10
5 5
0 0

= Waste operations
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 Operator Balance Chart

Current Operator Balance Chart

Takt Time = 45 Secs

45
40
35
30
25
20
15
10
5
0

1 2 3

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 Operator Balance Chart

Improved Operator Balance Chart

Takt Time = 45 Secs

45
40
35
30
25 This work has been
20
redistributed to the
15
10 other two employees
5
0

1 2 3

HOW WAS THIS DONE???

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 Layout

 How can the physical process be laid out so one person can make one
piece as efficiently as possible?
Current Layout: Operation 2: Assembly

Operation 3: Paint Operation 1: Drilling

Operation 4: Final Assembly

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 Layout
Guidelines for Layout:
 Arrange the machines so that there is little or no room for WIP to accumulate between processes
 Arrange the machines so that the walk pattern of one operator is as efficient as possible
 Arrange the machines so that material replenishment is easily facilitated by a material handler
 Never compromise safety of the employees when redesigning a layout

Better Layout:
Operation 3: Paint
bly
em

Operation 4: Final Assembly

s
As
n 2:
tio
e ra
Op

Operation 1: Drilling

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 Layout
 Guidelines for Layout:
 Arrange the machines so that there is little or no room for WIP to accumulate between processes
 Arrange the machines so that the walk pattern of one operator is as efficient as possible
 Arrange the machines so that material replenishment is easily facilitated by a material handler
 Never compromise safety of the employees when redesigning a layout

Even Better Layout:

Operation 3: Paint

Operation 4: Final Assembly

Operation 2: Assembly

Operation 1: Drilling

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 Planning For Implementation

Designing a Flow Manufacturing

Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation
Step 5: Establishing Supermarket Requirements
Supermarkets are strategically placed inventory with
standard pre-determined quantities in order to:

7 hrs

SMT P4
P4 Assy
Assy Burn Pack
SMT FIFO P3
P3 Assy
Assy FIFO
Burn in
in FIFO
Pack

 Minimize inventory investment

 Maximize protection against disruption in flow due to:
 Fluctuation
 Demand
 Quality level
 Process times
 Physical location of supplying process
 Lengthy set up time

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 Planning For Implementation

Step 5: Establishing Supermarket Requirements

How can you analyze your WIP??
LOOK AT IT! and WATCH IT OVER TIME

BUFFER
LEVEL

What does this WIP Level indicate???

Good Buffer level
Covers us when we have a problem (beginning) but we
aren’t depleting
ACTION - Work on the “Rocks” and reduce further
We are running dry of WIP impacting Customer
- Still too much variability in the process
ACTION - must RAISE the buffer level until we can
resolve some of the problems, i.e. the “rocks
beneath the surface”

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 Planning For Implementation

Designing a Flow Manufacturing

Process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work

Step 5 - Establishing Supermarket Requirements

Step 6 - Establishing Resource Requirements

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 Planning For Implementation

Step 6: Resource Requirements

Operation (Takt Time= 20 min.)

10 20 30 40 50 60 70

Actual Process Times

19 m 18.5 m 17m 19 m 19.5 m 18 m 16 m

Total Lead Time = Number of Operators Required

Takt Time

127 min (sum of process time) = 6.4 Operators (Round Up to 7)

20 min

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 Planning For Implementation - Summary

We have completed six critical steps toward implementation a flow

manufacturing production process

Step 1 - Create a Value Stream Map

Step 2 - Develop Sequence of Operations (Work Content)

Step 3 - Takt Time Calculation

Step 4 - Balancing the Flow of Work
Step 5 - Establishing Supermarket Requirements
Step 6 - Establishing Resource Requirements

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