Lean Production

One piece production

Book: Monden’s chapter 7,9

Dr. Tran Duc Vi

IEM School - HCM IU
* Sep 2022 1
Today’s Question
● How fast could you make product/services and deliver to customers?
● How to shorten Lead Time?

Wait for a long time to get your food or drink?

Today Questions
● What is lead time?
https://www.youtube.com/watch?v=7sT14cxr02k

● How significant is lead time?

● How has your company/department reduced lead time?

● How has Toyota reduced lead time?

● Can you apply similarly?

Types of Lead time in a manufacturing system

● L1: Lead time of data

processing
● L2: Lead time of the
manufacturing activity
itself ---> TPS
● L3: Lead time of
delivering completed
products to customers
Some advantages of shortening Lead time
● Adapt quickly to changes in demand
● Reduce Work-in-process inventory
● Amount of “dead” stock on hand is minimal
How to reduce Production Lead time
Reduce 3
components:
● Processing time for
supply lots
● Waiting time between
processes
● Conveyance time
between processes
Framework for reducing Production Lead time
Shortening Processing Time at each process
Shortening Processing Time
Watch this experiment of “One-piece” vs. “Batch” production

Can you explain the result differences?

Envelope stuffing
https://www.youtube.com/watch?v=dmQORuNFE4c
Simulation with different batch sizes
https://www.youtube.com/watch?v=ZcHCUh6EGEI
● Batch of 10 ● Waiting time (waste)
● Motion (waste) ● WIP (waste)
Shortening Processing Time - Small Lot Size

What if absolute “One-piece

production” is impossible?
Shortening Processing Time - Small Lot Size

What if absolute “One-piece

production” is impossible?
- small lot production
- reduce setup time
(more in next lessons)
Shortening Processing Time - Small Lot Size
Processing time:
1minute/ unit

Lot size : 3000

Set up time of
alternating lots: 1 hour

Lot size : 300

Set up time of
alternating lots: 1/10
hour (6 min)

→ How much a lot size could be reduced?

Shortening Processing Time – Reduce setup time
Processing time:
1minute/ unit

Lot size : 3000

Set up time of
alternating lots: 1 hour

Lot size : 300

Set up time of
alternating lots: 1/10
hour (6 min)

→ if the setup time was reduced to 1/N of the initial time, the lot size could be
reduced to 1/N of its initial size without changing the loading rate of the process
Benefits of Setup Time Reduction

https://www.
youtube.co
m/watch?v=
bcIkuHqC71
o
Shortening Waiting time & Conveyance time between processes
Shortening Waiting Time Caused by Pre-Process Lot Size

It takes __ min for 1

product unit to go
through 3 processes

It takes __min for 600

product unit to go
through 3 processes

Process 1 Process 2 Process 3

1 minute 1 minute 1 minute
Shortening Waiting Time Caused by Pre-Process Lot Size

It takes 3 min for 1

product unit to go
through 3 processes

It takes 30 hr (600
min x 3) for 600
product unit to go
through 3 processes

Process 1 Process 2 Process 3

1 minute 1 minute 1 minute
Shortening Waiting Time Caused by Pre-Process Lot Size

If each single unit is

conveyed to the
subsequent process as
soon as it has been
processed by the
preceding process, the
total time required to
produce 600 units is:

_________________

Process 1 Process 2 Process 3

1 minute 1 minute 1 minute
Shortening Waiting Time Caused by Pre-Process Lot Size

If each single unit is

conveyed to the
subsequent process as
soon as it has been
processed by the
preceding process, the
total time required to
produce 600 units is:

600 minutes + 1 minute

+ 1 minute = 602
minutes.
Process 1 Process 2 Process 3
1 minute 1 minute 1 minute
Shortening Waiting Time - Conveyance Improvement
● Layout of machines
Flow shop vs Job shop
(functional) layout ?

● Quick conveyance means

Belt conveyor, chute, forklift
Whirligig beetle system, round-tour
mixed-loading system
 Summary: Framework for reducing Production Lead time

Next lessons
Summary
● Lead time
● Significance of lead time reduction
● How to reduce lead time?
● How has Toyota reduced lead time?