[精选]IE Line Design Module (Training Materials).pptx
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1、Industrial Engineering Line Design Procedure Expectations ExchangePlease tell us4Whats been the biggest challenge when designing or modifying a mechanical assembly line at your facility?4 From an Engineers point of view 4 From a Functional Managers point of view simple to execute with minimal opport
2、unity for error efficient enough to achieve the best value solution for our customer and our pany flexible enough to meet our ever changing customer demands Jabil must be able to react quickly to a customer change in our customers demands and a dynamic business environment.As a result of this shift,
3、we hav adjusted our manufacturing processes to conform to our customers ever changing needs Objectives of the SessionA consistent understanding of the Industrial Engineerings approach to Line Design within Jabils production environmentA toolkit of strategies and methodologies for successfully execut
4、ing line designs that are:4Simple to execute with minimal error4Flexible enough to meet Jabils ever changing customer demands4Efficient enough to achieve the best value solutions for Jabil and its customers By the end of this module,you will have:Philosophy/ApproachAs a group,brainstorm 4What do we
5、mean by“flexible,scalable,and modular line design at Jabil?4Flexible line design?4Scalable line design?4Modular line design?able to re-deploy all of the equipment to existing customers able to add work content to a workstation without major reconfiguration able to react quickly and with ease to chan
6、ging market conditions able to develop processes simple enough that anyone can perform able to adapt to unexpected changes of order volume for existing products able to add capacity to the line in small increments able to reconfigure an existing workstation quickly and cost effectively able to add s
7、tations without interrupting production able to source and utilize multifunctional equipment Philosophy/ApproachAs a group,brainstorm 4With regard to cost,what do we mean by“a flexible,scalable and modular line design in a cost effective manner?4Cost Effective?for Jabil&the customers design what is
8、needed,not just in case or excess design what customer need not what customer want simpler solution whenever possible cost justification to the affordability“bare bone does not mean the most effective way search for used but good equipment thru ww network sometime greater investment might be require
9、d upfront for different product life cycleBusiness Perspective4On the importance of“a simple system that is flexible,scalable and modular in a cost effective manner with minimum waste for Jabils dynamic business environment -Ken PinkleyPhilosophy/ApproachAs a group,lets respond to the Business Persp
10、ective 4What can you do to ensure that the engineers develop a simple system that is“flexible,scalable and modular in a cost effective manner with minimum waste for our customers and for Jabil?standardize the approaches coach our customers on cost effective processes make use of the suppliers for ne
11、wer and more cost effective technologies make the target/objective be visible to all engineers help others to practice lean manufacturing as well make others to understand wastes and value-add Line DesignA new customer has signed a contract with Jabil.The workcell manager is asking you to develop a
12、plan that outlines all the information that you need to know and how your team will design a mechanical assembly back end for new product“X.Assume that this is a Low Volume High Mix product.More specifically she is asking you to outline:4What information will you need in order to start the design?Do
13、cument using a bulleted list format that describes the information youll need to assess and successfully design a line.4What series of steps will you take to convert that information into meaningful data?Looking for a list,step 1,step 2,etc.4What kind of IE tools will you use to develop a line desig
14、n?At each of the steps listed above,what IE tools would you re mend to use?You have 20 minutes to Discuss and Document your ideas Summarize your out es to the entire Group,explaining any exceptions/differences Group Leaders-use mark up tools whenever possibleCase Study One-ApproachCase Study One:App
15、roach-Line Design 4What information will you need in order to start the design?Document using a bulleted list format that describes the information youll need to assess and successfully design a line.4What series of steps will you take to convert that information into meaningful data?Looking for a l
16、ist,step 1,step 2,etc.4What kind of IE tools will you use to develop a line design?At each of the steps listed above,what IE tools would you re mend to use?Information Data Conversion Steps IE TOOLS BOM Test plan Machines/equipment spec TAKT/cycle time Product metrics Yields Quality&workmanship std
17、Sample/drawings Demand variation Cost targets Product design Space required Resources constraints Materials lot size Production schedule Customer expectation Delivery pattern etc mon part breakdown Process flow chart Handling method Machines requirement MOST&time study Materials flow Customer expect
18、ation Demand forecast&analysis RFQ Layout etc Process flow chart MOST Auto Cad Cap Model Value stream mapping VA NVA analysis Simulation RFQ Layout FMEA etcLine Design Process MappingWhat must we know first?4What is to be produced?-understand the product mix4How much will be produced?-show a forecas
19、t,upsides,history4How will the product be made?use and scrub the BOM and review the Process Flow if available4How will the raw material arrive?Qty/Size?Per medium4What is the expected life cycle of the product?Sample timings,proto builds,production,end of life,customer production schedule4At what lo
20、cation will the product be manufactured?4What kind of manufacturing floor space has been assigned for this project?Line Design Process MappingAs a group,lets discuss 4Why is it important to properly analyze and categorize all of the data weve described?4How would you instruct your Engineers to inter
21、pret and organize this information?Do the right thing right,at the right time and right place,and at 1st time If you do not have the right info,the assumption might be based on inaccurate judgment or wrong data Theres no golden rule,a lot would be from experiences FM to guide the junior engineers AS
22、K,do not assume Line Design Process MappingThe first step is to Chart the information 4P-Q Product-Quantity Analysis4Objective Determine if product mix requires independent manufacturingLine Design Process MappingNext 4P-R Product-Routing Analysis4Results visibility to similar types of operations an
23、d similar types of products.Line Design Process MappingNext 4Q-R Quantity-Routing Analysis4Results visibility to material handlingLine Design Process MappingNext 4P-Q-T Product-Quantity-Time Analysis4Results balance between production staff and flexibility of the line4Results shows variation in volu
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