LLD-Process解读.ppt
Lean Line Design Process Standard Work for LLD-2011-Nov-282Approach Lean Line Design Collect the information.Convert information into meaningful data.Use IE tools to develop a line design Information Data Conversion Steps IE TOOLS BOM Test plan TAKT/cycle time Product metrics Yields Quality Plan Sample/drawings Demand variation Product design Space required Resources constraints Materials lot size Production schedule etc Process flow chart Handling method Machines requirement MOST&time study Materials flow Demand forecast&analysis RFQ Layout etc Process flow chart MOST Auto Cad Std Work Value stream mapping VA NVA analysis Simulation Layout PFMEA etc3LLD ProgressInformationanalysisThe goal is to develop a lean line that is flexible with zero non-value add baselineProduct-Quantity AnalysisLocationPFEP(Plan For Every Part)Line Capacity AnalysisProcessanalysisPFMEAProcess FlowMOST AnalysisValue Steam AnalysisTAKT TimeRough LayoutMachine Capacity DesignStandard Work&PoUP DesignMOST/HC/Line BalanceSimulate Cell Experiments&Trial RunDetails LayoutInvestment JustificationLine Setup and optimizeScheduleOEELine DesignDesign Review4pCustomer Demand&Product InfoCustomer Demand&Product InfoWhat is to be produced?-understand the product mixHow much will be produced?-show a forecast,historyHow will the product be made?use the BOM and review the Process Flow if availableHow will the raw material arrive?Qty/Size?At what location will the product be manufactured?What is the schedule?etc5pProduct-Quantity AnalysisP-Q(Product-Quantity)AnalysisDetermine if product mix requires independent manufacturing6pLine Capacity AnalysisLine Capacity AnalysisLine capacity analysis must rely first on historic information and the best forecast information possible.Do not consider overtime hours or additional shifts as Available Work Hours.Available Work Days=450days(2 shifts per day/5 days per week/45 weeks per year)7pOEEOEE(Overall Equipment Effectiveness)Analysis8pMOST AnalysisMOST AnalysisMOST will enable the operator to combine the operator and material flow charts into one series of assembly stepsTo determine TAKT time of each productWhen developing a MOST analysis,we should consider Zero non-value add baseline Space allocated Process flow chart Flexible manufacturing line Zero waste Materials handling systems Standard equipment etc9pPFMEA PFMEA can be used as a tool to measure the gap between the proposed process steps and their potential performance it will enable an analysis of process failures early enough in the design process10pValue Stream Mapping Value Stream Mapping to assure that the designed operational assembly sequences steps have the least amount of wasteValue Add(VA)Typical VA Activities:-Cold/Hot Roll-Smelting-Bauxite digestion-Alumina precipitation-Stamping/Fabricating-Printing-AssemblingNon-Value Add(NVA)Typical NVA Activities:-Counting-Handling-Inspecting-Transporting/Moving-Stocking/Storing-All Rework Loops-Signoffs(approvals)-Delays(waiting time)Business Non-Value Add(BNVA)Typical BNVA Activities:-Order Entry/Processing-Purchasing-Bauxite disposal-Pot lining disposal-Sales/Marketing-Regulatory reporting-Internal Financial Reporting-Point of use material/tool retrieval11pStandard WorkStandard Work A Standard Work is a combination of men,materials and machine to carry out production in a maximally efficient way.Standard Work is different from Standard Operation Procedure12pPFEPPFEP(Plan For Every Part)-A database to store all data about each part we are using.13pRough LayoutDevelop Rough Layout:(using process flow with Auto time and Manual time)14pDetails LayoutDevelop any other functions that are related to the process(rework area,reject material on line,FSA station etc.)Manipulate and adjust for good fit and functionChallenge each individual layout with Lean Principles15pApply Lean PrinciplesSynchronize Production with Customer Demand(Produce to the Takt time)Identify and Get Rid of Non-Value Added ActivitiesDevelop Continuous Flow(one-piece-flow)Wherever Possible Use“Supermarket”kanban and WIP Caps to Control Production Where Continuous Flow Is Not PossibleManage the Time TrapLevel the Production Mix and VolumeReduce Changeover Times,Downtime,DefectsReduce Batch SizesThank you
