ASQ How To Improve Process Performance Using Lean Automation PDF
ASQ How To Improve Process Performance Using Lean Automation PDF
Frank Garcia
New Machine
I Process I
Step 2
“After
After implementing lean
improvements such as cellular
manufacturing and setup reduction,
selective automation can add value
and
a d reduce
educe human
u a variability.”
a ab ty
Richard Schonberger
Lean Manufacturing
Fundamental Principle of Lean Manufacturing
Any activity
A ti it or action
ti which
hi h
does not add value to the
product
d t is
i a form
f off waste
t and d
must be eliminated or
minimized.
i i i d
Definition of Value -Added
• Value is added any time the product is
physically
y y changed
g towards what the
customer is intending to purchase.
* Used
* Usedmost frequentlyprior
most frequently priorto to Automation
Automation
Value Stream Map
An Assessment Tool
• The value
al e stream map follo
follows
s the prod
production
ction
path from beginning to end and shows a
visual representation of every process in the
material and information flows
Schedules
I
Process I
Equipment
Raw
y Cycle
y Finished
Materials
Times Goods
y Change
Over
y Reliability
y Error
E Rate
R t
Lead
Time
File: VSM-A1
Value Stream Map (Current State)
Orders Every 2 Weeks
Production Control
New Jersey Randomly Placed
Andrea Aromatics Alanx Order as Needed Various
Porcelain Orders (Various Sizes)
(Scented Oils) (Shaped Stones) Customers
(Round Stones)
Average of 6,000
Stones per Day
in Various Size
Orders (8 to 20 case
& 200 to 400 case
range mainly)
30 Cans of Oil 59,000 Stones 50,000+ Stones
Every 2 Weeks
k Every 2 Weeks
k Every 2 Monthsh
(via stringer)
Bi-
Weekly Daily Shipping
Productio Orders
n Daily
Schedule Shipments
APAI
Multiple Ameripack Manual Manual
Automatic
Batch Tanks Flow Packager
I I I Stapler I I I
up to 0 0
125 Cans of Oil 1 Operator 4290 1 Operator 1/2 Operator 1/2 Operator 90,504 1 Operator
250
20,640 Round Stones Stones Stones
stones
49,000 Shaped Stones
in WIP
C/T = 25 - 65 min. C/T = 1 sec. C/T = 3 sec. C/T = 2 sec. C/T = 1 sec.
C/O = 10 min. C/O = 5 min. C/O = 2 min. C/O = N/A C/O = N/A
Rel. = 100% Rel. = 85% Rel. = 80% Rel. = 100% Rel. = 100%
11.6 Days 0.7 Days 15.1 days 27.4 Days Lead Time
65 minutes, 7 seconds
65 min. 7 seconds
Value-Added Time
Value Stream Map (Future State)
Orders Every Week
Average of 6,000
Stones per Day
in Various Size
Orders (8 to 20 case
& 200 to 400 case
Bi-Weekly range mainly)
12 to 16 Cans 30,000 Stones 25,000 Stones Production
off Oil
il Once a Once a Weekk Once a Monthh S h d l
Schedule
Week (via stringer) (large
orders)
Daily Shipping
Orders
Daily
Shipments
4 Cases
APAI
Multiple Ameripack Manual Manual
Automatic
Batch Tanks Flow Packager
I I I Stapler I I
up to 0 0
75 Cans of Oil 1 Operator 4290 1 Operator 1/2 Operator 1/2 Operator 30,000 1 Operator
250
40,000 Round Stones Stones Stones
stones
25,000 Shaped Stones in a supermarket
in WIP
type arrangement
C/T = 25 - 65 min. C/T = 1 sec. C/T = 3 sec. C/T = 2 sec. C/T = 1 sec. with stocking levels
C/O = 10 min. C/O = 5 min. C/O = 2 min. C/O = N/A C/O = N/A by shape and scent
Rel. = 100% Rel. = 85% Rel. = 80% Rel. = 100% Rel. = 100%
Increase
10.8 Days 0.7 Days 5.0 days 16.5 Days Lead Time
Reliability
65 minutes, 7 seconds
65 min. 7 seconds
Value-Added Time
VSM IMPLEMENTAION
FUTURE STATE IMPLEMENTATION PLAN & SCHEDULE
SEQUENCE COMPLETION
LOOP OBJECTIVES PROJECTS (PRIORITY) DATE (Mon./Yr)
Supplier Loop * Develop pull system with suppliers 1. Review Weekly/Monthly Requirements With Suppliers 1 Sep-01
* Increase number of deliveries per week 2. Revise current blanket orders 1 Sep-01
* Reduce raw material inventory to match 3 Send daily consumption data to suppliers
3. 2 Nov-01
Nov 01
4. Setup point of use raw material areas 1 Oct-01
Production Control Loop * Implement daily shipping schedule 1. Single point to schedule( shipping). See pacemaker loop. 1 Oct-01
* Work to schedule manufacturing based on
shipping requirements 2. Daily production schedule by Operations Manager 1 Oct-01
3. Implement kanban loops as shown on future state VSM 2 Nov-01
4. Use MRP for materials forecasting 1 Oct-01
Element * Reduce lead time 1. Eliminate WIP between winding & annealing 1 Sep-01
Loop * Develop continuous flow 2 Implement supermarket for element prep and kanbans
2. 1 Oct 01
Oct-01
* Develop pull system with element prep
supermarket 3. Crosstrain element assembly operations 2 Dec-01
Module Assembly Loop * Reduce cycle time 1. Analyze process variance in environmental test 1 Oct-01
* Reduce variation in cycle time in testing 2. Analyze process variance in module drydown 1 Oct-01
* Reduce variation in cycle time in drydown 3. Implement supermarket and kanbans for cell installation 1 Oct-01
* Establish pull system with supermarket from
cell installation 4. Crosstrain module assembly operations 2 Dec-01
* Reduce use of carriers 5. Analyze need for carriers vs. subassembly units 1 Sep-01
6. Analyze material handling reductions and layout
improvements for element prep operations 3 Jan-02
7. Set up leak tested subassembly units in supermarket for final
assembly 1 Oct-01
Pacemaker Loop * Reduce cycle time 1. Improve assembly methods in final mechancial assembly 2 Dec-01
* Establish pull system with supermarket from 2. Review design for manufacturing assembly improvements for
(Unit Assembly/Shipping Loop) shipping tubing assembly 3 Feb-02
3 Consolidate
3. C lid t inspection
i ti with
ith final
fi l mechanical
h i l assemblybl or
shipping/packing 2 Nov-01
4. Set up raw material suppermarket for final assembly 1 Oct-01
5. Crosstrain unit assembly operations 2 Dec-01
NOTES:
1. Conduct kanban and point of use training for plant personnel in 2001.
2 Priotities as follows: #1(Complete in 2 months),
2. months) #2(Complete in 4 months),
months) #3(Complete in 6 months)
3. Consider use of teams for implementation after training.
Implementing Lean Changes
“My conclusion is that all of us making a lean leap
will need to deal with capability
p y issues (TQM/Six
(
Sigma) and with availability issues (TPM) while
removing wasted steps and introducing flow and
pull in every value stream (TPS). My further
conclusion is that there is no “right sequence” to
follow in tackling these problems. Rather it
depends on the nature of the product,
product the nature of
the process technology, and the nature of the
business.”
1-3σ:
1 3σ: Development of SOPs and process audits
WORST
Improvement
Automation
Implementation Information
DO IT!
Plan Systems
Levels of Automation
Load Machine Unload Transfer
Levels Machine Cycle Machine Part
2 O
Operator AUTO O
Operator O
Operator
• Cellular Manufacturing
g & Layout
y
• Balance Cycle
y Times Between Work Stations
Later changed
to U Shaped Cells
WORKSTATION CYCLE TIME: 25sec., 1.25 min. REJECT
DATA
Cell Changes
PER 3 UNITS
2 5 to 8%
• Root Cause Analysis
LED
TEST
7
SOLDER
SAMPLES
4 5 6 8 9
& CUT
• Pareto Analysis
ATTACH
BACK
ASSEMBLY CONTACTS BUTTON & GLUE
COVER,
#1 ASSEMBLY BATTERY SWITCH/
STAKE PACK
1
LED COLD STAKE & ASSEMBLY ATTACH
STRAP &
PLACEMENT TEST PCBs SOLDER LABEL STRAP
ATTACH
STRAP
INSERT
TEST LED REJECT
SWITCH
PCBs SOLDER DATA ACTIVATOR
& CUT
1 ASSIST
REJECT
3 DATA <0.1%
AFTER CHANGES WORKSTATION CYCLE TIME: 25sec.,
1.25 min. PER 3 UNITS
TEST
4 SAMPLES
1 2 3 5 6
ATTACH
BACK
PCBs
PCB ASSEMBLY CONTACTS BUTTON &
COVER,
GLUE
#1 ASSEMBLY BATTERY SWITCH/
from COLD STAKE & ASSEMBLY
STAKE
ATTACH
PACK
STRAP &
supplier TEST PCBs SOLDER LABEL
ATTACH
STRAP
STRAP
REJECT INSERT
DATA SWITCH
ACTIVATOR
Lean Six Sigma Changes
• Cold staking fixtures
(Poka Yoke)
Production Control
(normally working Randomly Placed Various Distributors
Sheet Galvanized Sheet Galvanized Sheet Galvanized Sheet Galvanized Orders (normally
24 to 48 hours ahead (~ 24 for Smith Corp. &
Steel (4’ by 8’ or cut) Steel (4’ by 8’ or cut) Steel (4’ by 8’ or cut) Steel (4’ by 8’ or cut) single unit orders)
of ~ 6 for Jones Systems
promised shipment)
Daily Daily
Up to an average Daily
Production Production
of 130,000 lbs Shipping Daily
Reports Reports
daily in peak Schedule Shipments
season
In Straight
Panel Dept.
Shear Notch Specialty Punch Corner Punch Bend Stake & Label Add Z Brace Radius & Band Rack Shipping
1 Accurshear 1 Manual 4 Semi-Auto 3 Semi-Auto 1 Manual 1 Automated 1 Automated 1 Manual Table,
Automated Notcher (S-23) Punches Punches Brake (R-7) Machine (R-8) Machine (ACR) 1 Jig-less
Shear (P-3)
(P 3) & 1 Automated (S-1,
(S 1, S
S-2,
2, & S
S-3)
3) & 1 Automated Machine (R12),
I Notcher (R-3) Brake (R-13) & 1 Jig Machine
(R1)
2 to 5 days 1 Material
1 Operator 1/2 Operator 0 Operators 1 Operator 1/2 Operator 1/2 Operator 1/2 Operator 2 Operators 2 Operators
depending Handler
on pre-cut
size
C/T = 4 min. C/T = 2 min. C/T = 2 min. C/T = 2 min. C/T = 5 min. C/T = 2 min. C/T = 7 min. C/T = 8 min. C/T = N/A
C/O = N/A C/O = 4 min C/O = N/A C/O = up to C/O = 30 to C/O = N/A C/O = N/A (average) C/O = N/A
Rel. = 99% Rel. = 95% Rel. = 99% 30 min. 60 sec. Rel. = 99% Rel. = 98% to C/O = 2 to 30 Rel. = 100%
Rel. = 99% Rel. = 90% 99% min.
Rej = 5% 2 to 5 Working Days,
Uptime = 80%
Lead Time
2 to 5 days
Machine (R12),
& 1 Jig Machine
Work to 1 to 2 days lead time I (R1) 1 Material
Handler
2 Operators
Takt time = 5 min.
C/T = 8 min. C/T = N/A
(average) C/O = N/A
Rel. = 100%
C/O = 2 to 30
min.
What’s Causingg Reject rate = 5%
U i
Uptime = 80%
Evil Variation? 8 min.
2 to 5 Working Days,
Lead Time
UNDERSTANDING ROOT CAUSES of R12 PROBLEMS
CAUSE AND EFFECT DIAGRAM
Red = Most Important
p Causes
SET UP VALUES
CHANGE
NO SPECS
OPERATORS MEASUREMENT
RADIUS TEMPLATE
MAINTENANCE ACCURACY
PANEL
CHANGES
SQUARENESS
SETTINGS DIFFERENT SETUP
PROCEDURES NO DIMENSIONAL SPECS
OR TOLERANCES DIFFERENT
OPEATOR MEASURES USED ON
OPERATOR R1 & R12
PREFERENCE
JUDGEMENT
NO TRUST RADIUS ANGLES
STRAIGHT PANEL
(PANELS, STEEL) VARIES
3 SUPPLIERS
SPECIALTY PUNCH
Process Improvements
Lean
Based
• Online radius
measurement and
tracking
R13 Capabilities After Lean
Automation
• Operates as a cell
• Runs two product families
• Changeover in less than
5 sec. within and between
product families
• Cycle time reduced from
5 min. to 1.8 min.
• Realtime auto check of
each panel with data
collection
• Process capability at 4 to
5 sigma
Levels of Automation
Load Machine Unload Transfer
Levels Machine Cycle Machine Part
R13 2 O
Operator AUTO O
Operator O
Operator
• Functional layout
• Average batch size of
900 bearings
g
• Long set ups of 9 hrs
• Large amount of WIP
• Long lead times of 4
to 9 weeks
ee s
• 3 shift operation
BEFORE Lean Automation
Lean Techniques Used
Before Automation
• Product Family Value Stream Map
Level 4 Automation
Level 4 Automation
Smoke
S o e Detectors
etecto s
IS DEPT
INFO &
HARDWARE SOFTWARE REPORTING
CONTROL
Server Farm Large Fully Internet Portal
Large Database Integrated Or Extranet
Bus.
Bus Computers ERP/MRP II S
Supplyl Ch
Chain
i
System
Client/Server Large Networked to Intranet Portal
MES PCs Database Business
Web-based System
Industrial PC Small Small Control Ad Hoc
SCADA Bar Coding Database, Network
SCADA SW
PLC & PLC Program Programmable Printed
PLC Terminal Control Graphs
Office PC Spreadsheet
p Electrical Byy Hand
I/O Control or Printout
ENGINEERING
Lean Automation Real-time Data to
Control Variation for Six Sigma
• Supports Critical To Quality
(CTQ) objectives (3.4ppm
(3 4ppm
defects)
• Online measurement of
process parameters
t
• Provide real-time
real time controls as
limits are understood
R13 Process Controls & System Status
• Design
g and implement
p lean automation & data
collection
Reduced inventory
Improved quality
G t flexibility
Greater fl ibilit
Contact Information
Ad t D
Advent Design
i CCorporation
ti
Canal Street and Jefferson Ave.
Bristol, PA 19007
www.adventdesign.com
800--959
800 959--0310
F k Garcia,
Frank G i Director
Di t Planning
Pl i & Productivity
P d ti it
[email protected]