Inspect
Transport Process
Inspect
Process
Transportation is integrated into the production process via automation e.g., moving line
Inspect
Process
Inspect
Transport
•Adjusting a production schedule to meet unexpected changes in customer demand
Sequencing
•Ordering the production in such a fashion to achieve the desired TAKT for all items
Quality,Quality,Quality…DefectsaretheWorstKWainitdinogfWaste
Batch
Building Quality into the Process Single Piece Flow
Single Piece Flow
From: The Toyota Production System
Production Line Cell 6
Part Number All Parts
Part Name
All Tubes
Operator
Orbital Weld
Flex
Weld
End Finish
Weld
End Finish
Torch Braze
Mech. Clean
Mech. Clean
Mark
Hydro Test
Outside Cell FPI X-Ray EDM
Weld
End Finish
Scope of Operations
From: Raw material To: Finished Goods
Quality Check
Safety Precaution
Standard Work-in-Process
The next process is the customer … never send defects ! 4
Check, Do, Verify
Gets you into Parts Per Million qualityWhen you verify your work, you catch 1
flaw in 100 parts. The next person checks your work and can catch 1/100 so that’s 1/10,000. Then that person Verifies their work and can catch 1/100. That’s 1/1,000,000 errors that can get through.
The next process is the customer … never send defects !
Check, Do, Verify
Check - The previous operators work. Do - Your work. Verify - That you did your work correctly.
TenantsofSinglePieceFlow
7TypesofWaste
DoNotMakeDefects
DefectiveParts OverProduction
DoNotPassAlongDefects
Inventory Motion
DoNotAcceptDefects
Transportation
Process
Building Quality into the Process 2 ways to perform SPF
Transportation is integrated into the production process via human conveyance e.g., Chaku-Chaku
Average by total volume
Average by
• As one person finishes their element, so do all. Work is then moved down the line synchronously.
• Every person is empowered to stop the production process if a reject is spotted.
Single Piece Flow catches Defects immediately • When you find a Defect
• You only have one • You know where it occurred • You Can find/Resolve the Root Cause immediately
Check, Do, Verify
9
One Piece Flow
Your customer is the next step in the process. Give to your customer, exactly what they need ( 1 item), exactly when they need it, done perfect every time.
e
GPS for GPC
Heijunka
Level Loading
taken from memory Jogger
•Finding a balance between the volume of work
that your organization needs to do and your
capacity
Material Information Empty container Full container 1 Sequence / Timing
4
Mech. Clean
Mech. Clean
Mark
Hydro Test
Cell or Chaku-Chaku line
2
1
Assembly Line
13
JIT Jidoka
process of any problem. - an obligation to stop the process until any
problem has been resolved.
Single piece or one piece flow is a means to primarily build Quality into the process. This is achieved by establishing a takt Time, developing std work, and swip. The premise is that an Operator can only work on one piece at a time, and performs a Quick quality check on the CTQs of the process before moving The part to the following process. If a defect is detected, Jidoka Is enacted…the line is stopped, and immediate action is taken To remediate the situation and take countermeasures to prevent reoccurence
Pull Production Methodology & Sequence
Definition
System of manufacturing in which the final process withdraws the parts it needs from the preceding process at exact timing intervals, in the exact standardized amount needed.
Sample Inspect catches Defect too Late • When you Finally Find a Defect
• How many more do you have? • Where are they in the process? • What is the root Cause?
• Takt time • Std work
Flow: work (process) that is done in onjunction with or simultaneous to transportation
7
One Piece Flow
• The production is organized into a synchronous chain where each person has a balanced amount of work relative to his/her supplier and customer in the chain.
Check, Do, Verify
Every Customer in a Process has:
- a right to expect perfect material - an obligation to inspect the material before use. - an obligation to inform the previous step in the