LEAN FLOW TECHNOLOGY

Transcription

1 LEAN FLOW TECHNOLOGY - MODULE LFT103 - MIED-MODEL LINE DESIGN

2 LEAN FLOW TECHNOLOGY MIED-MODEL LINE DESIGN PURPOSE Lean Flow Technology Line Design Concept. Resources Calculation. Line Design. Daily Resources Management. Flexible Operations. Response Optimization. Operational Definition. "At or Below" TAKT Time Target. Operational Method Sheets. Safety TQC Work Verify. Quality Management. Layout on Paper.

3 MIED-MODEL LINE DESIGN OVERVIEW Mixed-Model Line Design. Product CDT CDT Dc Product CDT CDT Terminal Assembly Process ( Par Process ) Panels Assembly Panels Test Machine Rapid Response. Overall Process Productivity. Increase Quality. Optimize Material Presentation. Optimize Resources Utilization. H(S) TAKT Time = Σ Dc ( Per Process ) 4 MAGIC NUMBERS ( At Capacity ). Σ Dc. TAKT Time ( Per Process ). ATw. Resources.

4 MIED-MODEL LINE DESIGN MIED-MODEL MANUFACTURING Mixed-Model Manufacturing. Product Demand Linked with Process Requirements to Produce. Highest Mix Possible. Synchronized Flow. Group Work to Time Targets. OP01 OP02 OP03 OP04 OP05 OP06 OP07 OP08 RIP03 OP12 OP21 OP32 OP31 RIP01 To Install Plant and Equipment. Data Created Help Run Process each Day. OP11

5 MIED-MODEL LINE DESIGN LINE DESIGN CALCULATION FLOW Product CDT CDT Dc s Required / Optional % Dc Product CDT CDT Yield Process Terminal Panels Panels Ass'y Ass'y Test Process Machine Terminal Panels Panels Scrap R R R Product Ass'y Ass'y Test R R R R Process Machine R R Terminal R Panels Panels % 105% 105% R 2 R Product O 22% Ass'y O 22% Ass'y Test CDT 110% 110% 108% 108% Machine % 112% 112% % 1% 2% CDT 200% 100% 22% 22% CDT 2% 2% 3% 3% % 1% 4% CDT 5% 2% 5% 10% Actual Time from SOE s Product CDT CDT Terminal Ass'y Process Panels Panels Ass'y Test Machine R R R LFT Σ Dc TAKT ATw Resources

6 MIED-MODEL LINE DESIGN SUM OF DEMANDS AT CAPACITY Total Volume that Consumes Resources in Each Process. Influenced by Process Factors : Required or Number of "Pulls" on Process ( R ). Recoverable Yield ( Y ). "REWORK". Impact through all Processes used to REPAIR PRODUCT. Non-Recoverable Yield ( S ). "SCRAP". Impact through all Processes used to BUILD A NEW PRODUCT. Σ ( Dc x R x Y x S ) Dc : Demand at Capacity. R : Required Work %. Y : Yield Influence %. S : Scrap Influence %.

7 MIED-MODEL LINE DESIGN REWORK AND SCRAP IMPACTS REWORK Test 10% Terminal Plate Assembly Panels Test Panels Assembly SCRAP Panels Assembly 10% SCRAP Panels Test 15% Product CDT CDT Terminal Ass'y R R 2 Process Panels Panels Ass'y Test Y 90% Y 90% S 10% S 15% Y 90% S 5% S 10% S 5% Test Rework O R10% R R Product CDT CDT Process Terminal Ass'y Panels Ass'y Panels Test Test Rework 110% 110% 10% R 126% 232% 126% 116% 116% 115% 105% 105% R R

8 MIED-MODEL LINE DESIGN NUMBER OF REWORK LOOPS REWORK 2 Test 3% REWORK 1 Test 5% Terminal Plate Assembly Panels Assembly Panels Test S Dc? S Dc? SCRAP Panels Test 3% Rework Loop 1 Rework Loop 2 Product CDT CDT Terminal Ass'y 126% 232% Panels Ass'y 110% 126% 116% 116% Process Panels Test 110% 115% 105% 105% Rework 1 Test 5% R R R 9% Rework 2 Test 3% R R R 9%

9 ALL FACTORS ROLLED PROCESS MAP OVERVIEW Product CDT CDT CDT FRU111 L101 Brazing 109% 218% 218% 218% 109% 210% 102% Process L101 Test Machine L101 Packaging 109% 10% 109% 113% 113% 10% 100% 109% 100% 100% 105% 100% 102% 100% Rolled-Up Volume Percentages on a 100% basis After having Considered : Required and Optional Work %. All Loops Rework Impacts %. Scrap and Cascading Impacts %. Defining how Frequently a Process is consumed by a Product. Mixed-Model Process Map with ONLY ONE NUMBER.

10 ALL FACTORS ROLLED PROCESS MAP PROCESS MAP EAMPLE Description Product TWK 530 NBL TWK 530 NBL-OC CDT TWK 536 NBL TWK 536 NBL-OC TWK 048 NBL TWK 048 NBL-OC HDM CDT CDT COIL 048 FRU % Process L101 L101 L101 Coils Unit Final Test Bending Brazing Machine Machine 205% 205% 200% 200% 100% 109% 105% 102% 102% 102% 100% 210% 109% 105% 102% 102% 102% 20% 105% 109% 105% 102% 102% 102% 20% 105%

11 SUM OF DEMANDS AT CAPACITY ALL FACTORS ROLLED % TO ONE NUMBER ( R x Y x S ) Product CDT CDT Terminal Ass'y R R 2 Process Panels Ass'y Panels Test Machine R R R R R R R R R R O 22% O 22% Product CDT CDT Process Terminal Panels Ass'y Ass'y Panels Test Machine 104% 105% 105% 110% 110% 108% 108% 105% 112% 112% 200% 100% 22% 22% Product CDT CDT Dc Product CDT CDT Process Terminal Panels Ass'y Ass'y Panels Test Machine Sum of Dc's :

12 MIED-MODEL LINE DESIGN TAKT TIME PER PROCESS From Sum of Demand at Capacity. Can be Different for Each Process. Variety of Process Factors. Machine Vs. Process Effective Work Hours. Shift Staffing Strategies. Process TAKT = H(S) Product Terminal Plate Ass'y Panels Ass'y Machine Panels Test Σ Dc CDT CDT Sum of Dc's : Effective Work Time per Shift (h) : Number of Shift(s) : TAKT Time (mn) :

13 MIED-MODEL LINE DESIGN TAKT TIME CALCULATION EAMPLES TAKT = H(S) Σ Dc ALE FEEDER TEST REWORK H = 7.3 hours S = Products (EOL) ALES Required = 200% TEST Yield = 90% MAIN ASS'Y TEST PACK BY PROCESS : MAIN ASS'Y : ALE FEEDER : TEST REWORK : TEST : PACK : Dc = Dc = Dc = Dc = Dc = TAKT = TAKT = TAKT = TAKT = TAKT =

14 TOTAL TIME FROM SOE s OVERVIEW For Operational Definition. Setup and Move : Include Dynamic Setup. Ignore Static Setup. Overlapping Times : Take Longest of Overlapping Times. For Total Product Cycle Time. TPc/t. Look at One Product as it is Pulled Through the Process. Include ALL Setup and Move Times. Overlapping Times : Take Longest of Overlapping Times. For Daily Resource Planning. Include ALL Setup and Move Times. Overlapping Times : Include ALL Overlapping Times, not just the longest.

15 TOTAL TIME FROM SOE s "OVERLAPPING" C C C C C C WS Seq. # Product P/N TWK NBL/NBL-OC / CDT / / CDT Overlap Task VA Mach Setup D/S Qty I/E SEQUENCE OF EVENTS Required Mach Mach Move D/S Qty I/E Dist. TQC Process I.D. Compressor Assembly Line Quality Criteria / Safety Description Supply Compressor Install Compressor to Weld Base Op. A Insert 4 shock absorbers Op. B Part Number : COMP42 Tolerance : 1±0.2mm Connect HP Test Flexible to Compressor D I Test Compressor Op. A 4.0 High Pressure : 300PSI Control Leaks Level Op. A 2.0 Maximum Leaks Level : 3 Tasks performed Concurrently. Take Longest of Overlapping Times : For Operational Definition. For Total Product Cycle Time Calculation TPc/t. Include ALL Overlapping Times, not just the longest : For Daily Resource Planning.

16 PROCESS MAP TIME OVERVIEW Product CDT CDT CDT FRU111 L101 Brazing Process L101 Test Machine L101 Packaging Work Content required, by Process, to transform each Specific Product. Total Times come Directly from Sequences of Events are used to complete Process Map Time. Time. Machine Time. Other Definition of Mixed-Model Process Map with : ONE LABOR TOTAL TIME, ONE MACHINE TOTAL TIME, by Product and Process Relationship.

17 PROCESS MAP TIME EAMPLE Description Product TWK 530 NBL TWK 530 NBL-OC CDT TWK 536 NBL TWK 536 NBL-OC TWK 048 NBL TWK 048 NBL-OC HDM CDT CDT COIL 048 FRU Process L101 L101 L101 Coils Unit Final Test Bending Brazing Machine Machine

18 ACTUAL TIME WEIGHTED ATw OVERVIEW CALCULATION Looks to Sequence of Events SOE's. Total Time Estimates. Based Upon Mix at Capacity. "We cannot predict exactly what the Next Product will be but we can estimate the Time the Next Product will take". ATw = Σ ( Dc x AT ) Σ Dc AT : Total Time from SOE s. Dc : Demand at Capacity.

19 ACTUAL TIME WEIGHTED ATw CALCULATION EAMPLE Description Product Demand at Capacity (Dc) Total Time SOE's (AT) (Dc*AT) TWK 530 NBL TWK 530 NBL-OC CDT TWK 536 NBL TWK 536 NBL-OC CDT Sum : Actual Time Weighted - Atw (mn) : 14.5 Average (mn) : 24 ATw = Σ ( Dc x AT ) Σ Dc 4650 = 320 ATw = 14.5 mn

20 RESOURCES #Op OVERVIEW CALCULATION Actual Time Weighted divided by the Takt Time. Number of : People. Machines. Pieces in One Machine. Operations, or Work Stations. Rounding Up for Operational Definition. #Op = ATw TAKT ATw : Actual Time Weighted. TAKT : Takt Time.

21 RESOURCES #Op A TYPICAL CASE OF Process Description Product Dc Terminal Plate Ass'y Panels Ass'y Panels Test Machine TWK 530 NBL ATw #Op = TAKT TWK 530 NBL-OC TWK 536 NBL TWK 536 NBL-OC CDT CDT TAKT = H(S) Σ Dc Sum [Dc*AT] : Atw (mn) : TAKT Time (mn) : #Op : ATw = Σ ( Dc x AT ) Σ Dc

22 RESOURCES #Op IMPLEMENTATION CONSIDERATION OP s Stations ATw #Op = TAKT = 4 OP OP OP10 OP20 OP30 OP40 4 4

23 DAILY DEMAND MANAGEMENT OVERVIEW LINE DESIGN : ONCE TO Dc ATw TAKT = RESOURCES Dc Machine ATw = Σ ( Dc x AT ) Σ Dc DAILY MANAGEMENT : ONCE TO Dr Σ ( Dr x AT ) H x S = RESOURCES Dr People To serve DEMAND Dr = Daily Rate. (Number of Products)

24 DAILY DEMAND MANAGEMENT A TYPICAL CASE OF # Operation Process Steel Boxes Forming Panels Assembly Panels Test Panels Packaging TOTAL # Op's : Resources - Dc : Resources - Dr : Staffing At DAILY RATE Staffing At CAPACITY

25 DAILY RATE MANAGEMENT FLOW RATE Fr Flow Rate can Measure the Performance or our Process. At the End of Line, or a Key Process. Critical Machine. High Machine Utilization. Provides Quick Feedback on Goal of achieving the Daily Rate. Quick Warning to Detect Problems. Monitored over 1 Hour or less. Fr = Dr HA(S) Dr : Daily Rate. HA : Available Work Time per Shift. S : Number of Shift(s).

26 HIGH, AVERAGE AND LOW TIMES OVERVIEW Work Content Time Ranges. Compared to ATw. Helps Describe Real Conditions. For In-Process Kanban Sizing. Considering Flexible Operations. Establishing Sequencing Rules. Process Sum of Dc's TAKT Time ATw AT High AT Average AT Low

27 HIGH, AVERAGE AND LOW TIMES FLEIBLE OPERATIONS TAKT : 7 mn TAKT : 7 mn TAKT : 7 mn OP10 OP20 OP30 OP40 ATw : 24 mn OP10 OP20 OP30 OP40 AT LOW : 20 mn OP10 OP20 OP30 OP40 AT HIGH : 33 mn TAKT : 7 mn OP10 OP20 OP30 OP40 OP10 OP20 OP 25 OP30 OP40 AT HIGH : 33 mn OP25

28 FLEIBLE OPERATIONS PROJECTED WORK AT OPERATION Process Terminal Plate Assembly Terminal Plate Assembly Control Panels Assembly Control Panels Test Control Panels Packaging Sum of Dc's TAKT Time ATw AT High AT Average AT Low Resources #Op Decision??? Projected Work at each Op : High Average Low Compared to TAKT Time???

29 FLEIBLE OPERATIONS FINAL DECISION Process Terminal Plate Assembly Terminal Plate Assembly Control Panels Assembly Control Panels Test Control Panels Packaging Sum of Dc's TAKT Time ATw AT High AT Average AT Low Resources New #Op Decision Projected Work at each Op : High Average Low Compared to TAKT Time???

30 DAILY DEMAND MANAGEMENT FLEIBLE OPERATIONS Process Steel Boxes Forming Panels Assembly Panels Test Panels Packaging TOTAL % # Flexible Op : # Op's : % Resources - Dc : % Resources - Dr : %

31 DAILY RESOURCES MANAGEMENT SETUP CONSIDERATION Description Product TWK 530 NBL TWK 530 NBL-OC TWK 536 NBL TWK 536 NBL-OC CDT CDT Dc S/U Forming Machine Sum of Dc's : Process Machine Effective Work Time per Shift (h) : Number of Shift(s) : TAKT Time (mn) : Atw mn) : #Op : Highest Work : Lowest Work : Average Work : Resources Available : 2 2 Utilization % : 57% 74% Average Setup : Minimum Available for Setup : 709 Maximum Setups per Day : 11 Welding %

32 FAMILY OF PRODUCTS OVERVIEW FUNCTIONAL or REPETITIVE MIED MODEL Focus on "What is Common" instead of Differences. Similar Processes. Types of Work. Times of Work. Setup Times and Characteristics. Material Presentation. Resources Optimization. Powerful Benefits of Mixed-Model. Resources Utilization. Employees Flexibility. Similar Machines. Number of Kanban Containers.

33 FAMILY OF PRODUCTS POWERFUL BENEFITS OF MIED-MODEL Assembly Lines L01 L02 L03 L04 L05 Products FUS-001 FUS-002 FUS-004A PLG-145 S PLG-854 S 40A 40A 40A 63A 63A Demand at Capacity (Dc) Machine Maximum Daily Rate (Dr) (Dr/Dc) % 59% 94% 147% 70% 71% Machine Utilization Rate 50% 75% 125% 35% 55%? New Mixed-Model Line with 5 Machines : L01-L02-L03-L04-L05 All Products % 68% New Mixed-Model Line with 4 Machines : L01-L02-L03-L04-L05 All Products % 85% We can Increase the Utilization Rate, with fewer Machines, by Improving our Response Capability. TPM Recommendation : Dc = 85% of Machine Capacity.

34 FAMILY OF PRODUCTS POWERFUL BENEFITS OF MIED-MODEL Assembly Lines L01 L02 L03 L04 L05 Products FUS-001 FUS-002 FUS-004A PLG-145 S PLG-854 S 40A 40A 40A 63A 63A Demand at Capacity (Dc) Machine Maximum Daily Rate (Dr) (Dr/Dc) % 59% 94% 147% 70% 71% Machine Utilization Rate 50% 75% 125% 35% 55%? New Mixed-Model Line for Family of Products 40A with 3 Machines : L01-L02-L03 Products 40A % 83% New Mixed-Model Line for Family of Products 63A with 2 Machines : L04-L05 Products 63A % 45% We can Increase the Utilization Rate, with fewer Machines, by Improving our Response Capability. TPM Recommendation : Dc = 85% of Machine Capacity.

35 RESPONSE OPTIMIZATION OVERVIEW Process Sequence Challenged. Total Product Cycle Time Reduction. TPc/t. Parallel versus Serial? Physically Linking Processes. Eliminate Wait, Queues, and Moves. NVA. OPTIMIZE MAIMIZE INVENTORY TURNOVER CUSTOMER RESPONSE

36 TOTAL PRODUCT CYCLE TIME TPc/t Longest Path through Manufacturing Process. Calculated : From the SOE, according to Product Synchronization. Excludes Wait, Queue, Shift Offset, IPK's Wait, Process Variation, By Product, not Family of Products. 8.3 TPc/t =? Total Work Content =?

37 TOTAL PRODUCT CYCLE TIME TPc/t EAMPLES Before Reengineering After Reengineering TPc/t =? 10 TPc/t =?

38 TOTAL PRODUCT CYCLE TIME TPc/t OPTIONAL PROCESSES Without Optional Process With Optional Process TPc/t = 44mn TPc/t =?

39 TOTAL PRODUCT CYCLE TIME THROUGH OPTIONAL PROCESSES Optional Paths are usually Required 100% by an Individual Product. TPc/t is calculated by Product, NOT Family. But A Weighted Average of TPc/t in a Family could provide an Estimate of the Family TPc/t.

40 TOTAL PRODUCT CYCLE TIME AND REWORK PROCESSES If Rework Time and/or Volume are significant : We should consider Weighted Averaging of this Time. When Multiple Passes occur, define the Total Time per Rework Cycle Scenario, until Scrap. Pass Value Added Work Non-Value Added Rework Time Total Time Rework % Weighted Time % % % % 10 5 Scrap 200 5% 10 Total Time per Rework Cycle for TPc/t : 122

41 RESPONSE OPTIMIZATION TPc/t REDUCTION In SERIES? Or PARALLEL?

42 RESPONSE OPTIMIZATION TPc/t REDUCTION Continuous Process Improvement. Along TPc/t Path First : 1. Eliminate Non-Value Added Work. 2. Eliminate Quality Criteria. 3. Move Internal Setup to External. 4. Reduce Setup and Move Times. 5. Reduce Value Added Work Times. RIGHT ORDER

43 FLOW PROCESS LEAD TIME FPLT Actual Response Time through our Process Pipeline. Measured by Product, not Family of Products. FPLT TPc/t WAIT IPK's SHIFT OFFSET WORK CONTENT VARIANCE

44 RESPONSE OPTIMIZATION FPLT REDUCTION Continuous Process Improvement. 1. Eliminate Shifts Offset. 2. Eliminate Wait. 3. Resolve Imbalances to Reduce #IPK's. 4. Eliminate Work Content Variance. RIGHT ORDER FPLT = Customer Response Capability. = Work In Process in Pipeline. WIP. = Finished Good Inventory. FGI.

45 TOTAL FLOW PROCESS LEAD TIME ORDER FULFILLMENT PROCESS Total FPLT TRANSPORT INVOICE FABRICATION ORDER ENTRY CREDIT Individual FPLT

46 OPERATIONAL DEFINITION OVERVIEW TAKT = H(S) Σ Dc OP07 Tasks Grouped "At or Below" TAKT Time Target. Physical Place to Do Work, and One-Up, One-Down Flexibility. Consistent Process and Quality. Enables Flow of Product

47 OPERATIONAL DEFINITION VERY LOW TAKT TIMES PROBLEMS Safety. Fatigue, Loss of Attention. Quality. Time for doing TQC's and Verify? Productivity. Flex Time can dramatically decrease Productivity. < 0.3 mn RED FLAG! FLE Time TAKT Time (FLE / TAKT Time) % 8.7% 33.2% 2.9%

48 OPERATIONAL DEFINITION SEQUENCE OF EVENTS TAKT Time : 2.5 mn 2.4 mn 2.5 mn 2.5 mn 2.4 mn WS A 10 A 10 A 10 A 10 A 10 A 10 B 20 B 20 B 20 B 20 Seq. # C 30 C 30 C C C C D D D D Product P/N CONTROL PANEL TWK NBL/NBL-OC / CDT / / CDT Overlap Task Unpack electrical cap Install cap to control panel frame Fix 24V contactor 1 screw 1 washer 1 wire Fix 24V contactor 1 screw 1 washer Fix start relay to front support 1 screw VA Mach Setup D/S Qty I/E 0.2 D E OP A SEQUENCE OF EVENTS Required Install support to control panel 2 screws Use screws SCR23 Install fan capacitor 1 nut 0.8 Label : 4µF at the top Connect Wire N 7 to fan capacitor 0.3 M/F connector to Left plug Connect Wire N 7 to power contactor 0.3 M/F connector to Center plug OP B Install compressor capacitor 1 nut 1.1 Mach Mach Move D/S Qty I/E Dist. TQC Process I.D. Main Line Assembly Quality Criteria / Safety Description P/N : 45CG20AJ/45FG20AJ Left side Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 Use nut NUT89 Size 530 : 35µF Size 536 : 40µF Install Sub-Assembly terminal plate 2 screws 1.0 Use locations : A4 and A5 Connect Wire N 2 to fan capacitor 0.3 F connector to Left plug Connect Wire N 2 to power connector 0.3 Plug identification : "N1" Connect Wire N 21 to power connector OP C 0.3 Plug identification : "L1" Connect Wire N 20 to power connector 0.3 Plug identification : "N2" Connect Wire N 6 (Red) to power connector 0.3 Plug identification : "N2" Connect Groung Wire to groung connector 0.8 Plug identification : "Ground" Connect Wire N 4 (Black) to K5 contactor 0.7 Use K51 plug to connect Connect Wire N 5 (Blue) to 100µF capacitor OP D 0.8 Right plug Evacuate Sub-Assembly control panel to IPK 0.1 D E 0.2

49 SEQUENCE OF EVENTS VERIFY WS A 10 A 10 A 10 A 10 A 10 A 10 B 20 B 20 B 20 Seq. # Product P/N CONTROL PANEL TWK NBL/NBL-OC / CDT / / CDT Overlap Task Unpack electrical cap Install cap to control panel frame Fix 24V contactor 1 screw 1 washer 1 wire Fix 24V contactor 1 screw 1 washer Fix start relay to front support 1 screw VA Mach Setup D/S Qty 0.2 D E SEQUENCE OF EVENTS 60 Install support to control panel 2 screws Use screws SCR23 70 Install fan capacitor 1 nut 0.8 Label : 4µF at the top 80 Connect Wire N 7 to fan capacitor 0.3 M/F connector to Left plug 90 Connect Wire N 7 to power contactor 0.3 M/F connector to Center plug I/E Required Mach B Install compressor capacitor 1 nut 1.1 C 30 C 30 C 30 C 30 C 30 OP A OP B 0.6 Mach Move D/S Qty I/E Dist. TQC Process I.D. Main Line Assembly Quality Criteria / Safety Description P/N : 45CG20AJ/45FG20AJ Left side Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 Use nut NUT89 Size 530 : 35µF Size 536 : 40µF 110 Install Sub-Assembly terminal plate 2 screws 1.0 Use locations : A4 and A5 120 Connect Wire N 2 to fan capacitor 0.3 F connector to Left plug 130 Connect Wire N 2 to power connector 0.3 Plug identification : "N1" OP C 140 Connect Wire N 21 to power connector 0.3 Plug identification : "L1" 150 Connect Wire N 20 to power connector 0.3 Plug identification : "N2" VERIFY

50 SEQUENCE OF EVENTS TQC's WS A 10 A 10 A 10 A 10 A 10 A 10 B 20 B 20 B 20 B 20 B 20 C 30 C 30 C 30 C 30 C 30 C 30 Seq. # Product P/N CONTROL PANEL TWK NBL/NBL-OC / CDT / / CDT Overlap Task Unpack electrical cap Install cap to control panel frame Fix 24V contactor 1 screw 1 washer 1 wire Fix 24V contactor 1 screw 1 washer Fix start relay to front support 1 screw TQC Contactor Part Number TQC Start Relay Part Number TQC Wire N 7 to fan capacitor connection VA Mach Setup D/S 0.2 D E Process I.D. Main Line Assembly P/N : 45CG20AJ/45FG20AJ Left side Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 60 Install support to control panel 2 screws Use screws SCR23 Qty I/E Required Mach Mach Move D/S Qty I/E Dist. TQC Description Contactor P/N : 45(C/F)G20AJ Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 70 Install fan capacitor 1 nut 0.8 Label : 4µF at the top 80 Connect Wire N 7 to fan capacitor 90 Connect Wire N 7 to power contactor OP A OP B 100 Install compressor capacitor 1 nut 1.1 SEQUENCE OF EVENTS Quality Criteria / Safety M/F connector to Left plug M/F connector to Center plug Use nut NUT89 Size 530 : 35µF Size 536 : 40µF M/F connector to left plug With Wire N Install Sub-Assembly terminal plate 2 screws 1.0 Use locations : A4 and A5 120 Connect Wire N 2 to fan capacitor 0.3 F connector to Left plug 130 Connect Wire N 2 to power connector OP C 0.3 Plug identification : "N1" 140 Connect Wire N 21 to power connector 0.3 Plug identification : "L1" 150 Connect Wire N 20 to power connector 0.3 Plug identification : "N2" TQC's

51 OPERATIONAL DEFINITION STATIC SETUPS TAKT Time : 2.5 mn?? WS A 10 A 10 A 10 A 10 Seq. # Product P/N CONTROL PANEL TWK NBL/NBL-OC / CDT / / CDT Overlap Task Unpack electrical cap Install cap to control panel frame Set screwing machine - Check Torque Fix 24V contactor 2 screws 2 washers Fix start relay to front support 1 screw VA Mach Setup D/S Qty I/E 0.2 D E S 200 E SEQUENCE OF EVENTS Required Mach Install compressor capacitor 1 nut 0.6 Mach Move D/S Qty I/E Dist. TQC Process I.D. Main Line Assembly Quality Criteria / Safety Description Torque : 16 N.m P/N : 45CG20AJ/45FG20AJ Left side Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 A Install support to control panel 2 screws Use screws SCR23 B Install fan capacitor 1 nut 0.5 Label : 4µF at the top 80 Set crimping machine - Check wrench traction S 100 E Wrench traction : 80 N B Crimp Wire N M/F connector B 20 Use AA56 reference point Size 530 : 35µF Size 536 : 40µF B Install Sub-Assembly terminal plate 2 screws 1.0 Use locations : A4 and A5 C Connect Wire N 2 to fan capacitor 0.3 F connector to Left plug C Connect Wire N 2 to power connector 0.3 Plug identification : "N1" C Connect Wire N 21 to power connector 0.3 Plug identification : "L1" C Connect Wire N 20 to power connector 0.3 Plug identification : "N2" C Connect Wire N 6 (Red) to power connector 0.3 Plug identification : "N2" C Connect Groung Wire to groung connector 0.3 Plug identification : "Ground" C Connect Wire N 4 (Black) to K5 contactor 0.3 Use K51 plug to connect C Connect Wire N 5 (Blue) to 100µF capacitor 0.3 Right plug C Evacuate Sub-Assembly control panel to IPK 0.1 D E 0.2

52 STATIC SETUPS SPECIFIC OPERATION TO PERFORM S/U TAKT Time : 2.5 mn 2.5 mn 2.4 mn 2.5 mn 0P Poste WS A 10 1 A 10 1 A 10 1 A 10 1 A 10 1 B 20 1 B 20 1 B 20 1 B 20 1 C 30 1 C 30 1 C 30 1 C 30 1 C 40 1 C 40 1 C 40 1 C 40 1 C 40 1 Seq. # 10 Unpack electrical cap 20 Install cap to control panel frame 40 Fix 24V contactor 2 screws 2 washers 50 Product P/N CONTROL PANEL TWK NBL/NBL-OC / CDT / / CDT Overlap Task Fix start relay to front support 1 screw VA Mach Setup D/S 0.2 D E Install support to control panel 2 screws Use screws SCR23 70 Install fan capacitor 1 nut 0.5 Label : 4µF at the top 90 Crimp Wire N M/F connector Qty OP A OP B 110 Install Sub-Assembly terminal plate 2 screws 1.0 Use locations : A4 and A5 120 Connect Wire N 2 to fan capacitor 0.3 F connector to Left plug 130 Connect Wire N 2 to power connector 0.3 Plug identification : "N1" 140 Connect Wire N 21 to power connector 0.3 Plug identification : "L1" 150 Connect Wire N 20 to power connector 0.3 Plug identification : "N2" 160 Connect Wire N 6 (Red) to power connector 0.3 Plug identification : "N2" 170 Connect Groung Wire to groung connector OP C 0.3 Plug identification : "Ground" 180 Connect Wire N 4 (Black) to K5 contactor 0.3 Use K51 plug to connect 190 Connect Wire N 5 (Blue) to 100µF capacitor 0.3 Right plug 200 Evacuate Sub-Assembly control panel to IPK 0.1 D E Set screwing machine - Check Torque S 200 E Torque : 16 N.m 80 Set crimping machine - Check wrench traction S 100 E Wrench traction : 80 N I/E Required 100 Install compressor capacitor 1 nut 0.6 SEQUENCE OF EVENTS Mach Mach Move D/S Qty I/E Dist. TQC Process I.D. Main Line Assembly Quality Criteria / Safety Description P/N : 45CG20AJ/45FG20AJ Left side Size 530 : 3ARR3CT10V5 Size 536 : 3ARR3CT6A5 Use AA56 reference point Size 530 : 35µF Size 536 : 40µF

53 OPERATIONAL METHOD SHEETS OVERVIEW Graphical Representation, at an Operation : Safety Criteria Safety is Quality. Quality Criteria. Verify TQC's. Work. Information comes from Sequence of Events. Not Vice Versa. To reinforce the Training Employees receive "Off-Line" to the detailed Sequence of Events. LFT TOOL FOR EMPLOYEES FLEIBILITY

54 OPERATIONAL METHOD SHEETS A TYPICAL CASE OF

55 OPERATIONAL METHOD SHEETS SYMBOLS

56 OPERATIONAL METHOD SHEETS SAFETY CRITERIA Be aware of the Safety Issues related to this Operation. In Addition to Work Station Safety Regulations. Example : Using specific tool to eliminate injury risks.

57 OPERATIONAL METHOD SHEETS TQC's Inspect Critical Quality Issues performed by the Previous Operator. Next Operation Checks the Work to Quality Criteria once again. Successive Quality Checks. TQC's = "Touch for Quality". NON-VALUE ADDED INVESTMENT

58 OPERATIONAL METHOD SHEETS WORK The Work required to be performed at this Operation. In Order of Assembly. Components Description. Components Identification Item Number. Quantity. PERFORM WORK ONE CORRECT WAY

59 OPERATIONAL METHOD SHEETS VERIFY Quality Issues that you need to Verify have been done prior to this unit being completed at this Operation. When they are multiple ways to perform work, and ONLY ONE WAY IS CORRECT. If Verify concern a Critical Point, assure that they have performed the Work Correctly with TQC at the Next Operation. Verify = "Touch for Quality". NON-VALUE ADDED INVESTMENT

60 OPERATIONAL METHOD SHEETS LONG OPERATIONS VERIFY / All Verify in the End can be Critical for Quality. Hidden, or Inaccessible Tasks. Long Rework Times. To remove more parts. Scrap. WORK & VERIFY WORK & VERIFY /.. 28 VERIFY 5 CONSISTENT ACROSS THE ORGANIZATION

61 OPERATIONAL METHOD SHEETS KEY POINTS Visible Quick Reference. On Line. Shows WORK. Not Just a Picture of the Product. Always Eliminate Text and Unnecessary Details. YELLOW WORK to COLOR Sightedness. Close-Up of the One Correct Way to Do Work. Find Numbers in Order of Assembly. Creating Flow of Work on the Method Sheet. Linkage with Kanban's. Quick Recognition. Color Coding. One Source Document : Sequence of Events. LFT TOOL FOR EMPLOYEES FLEIBILITY

62 OPERATIONAL METHOD SHEETS GENERIC APPROACH BY FAMILIES Method Sheets by Product, or Generic Approach by Families? Reduce the Number of Sheets. Speed to Update. Clarity on Line. Time to Find Correct Method Sheet NVA. Training Off-Line to Detailed SOE s.

63 OPERATIONAL METHOD SHEETS STANDARDIZATION ACROSS SITE EMPLOYEE FLEIBILITY. Engineering Control Ease. More People Can do Updates. Library of Symbols. Eliminate Variation when Flexing. Training Standards. "Off-Line" and "On-Line" Trainings.

64 QUALITY MANAGEMENT OVERVIEW Quality Inspector OP130 OP140 In traditional batch manufacturing, there are a few nonproductive Quality determination actions performed by Inspector. In the LFT, Total Quality flow process, there are many Quality Checks and Verifications throughout the Process.

65 QUALITY MANAGEMENT VISUAL SIGNAL RED. Material Shortage. Quality Defect. When we have problems that have stopped the Line.

66 QUALITY MANAGEMENT TOUCH FOR QUALITY WS Seq. # Overlap Product P/N CLUTCH MODEL A / 001 / 002 Task VA Mach Setup D/S SEQUENCE OF EVENTS Process I.D. Main Line Assembly G Pull Clutch Sub-Ass'y from IPK 0.1 G G G Install key to shaft flask Fix flask to primary shaft Block up flask to primary shaft Torque : 135Nm Tolerance : J=0 G Lubricate expansion plug 0.3 G Crimp expansion plug Die Part Number A1-002 H TQC Flask Fixation Torque : 135Nm H Assemble cap protector 0.7 H Insert flexible connector 0.2 H Insert control flexible to connector 0.3 Spherical face clean H Fix flexible Qty I/E Required Mach Mach Move D/S Qty I/E Dist. TQC Quality Criteria / Safety Description OMS

67 QUALITY MANAGEMENT AUDITS LFM BASICS SAFETY Q PRODUCT In-PROCESS FINISHED GOODS

68 QUALITY MANAGEMENT SAFETY AUDIT SAFETY To Guarantee Individual Safety Protection Application. Protection Adapted according to the Risk. By Team Members. Permanent Audit. SAFETY Quality Customer Response

69 QUALITY MANAGEMENT LFM BASICS AUDIT LFM BASICS To Guarantee LFM Rules Application : Employees Ability - Mastery Program. Employees Flexibility. Perform Work to the Right Work Station. Operational Method Sheets. Cleanness of Tools and Equipment. Kanban Management Understanding. By Team Members. Permanent Audit.

70 QUALITY MANAGEMENT PRODUCT In-PROCESS AUDIT PRODUCT In-PROCESS To Guarantee Elimination of Defect Near The Point Where Work is Performed. "Touch for Quality" Checks. By Team Members, or Assembly Line Certified Employees. Permanent Audit.

71 QUALITY MANAGEMENT FINISHED GOODS AUDIT FINISHED GOODS To Guarantee Free Defect in Finished Good by Quality Inspection. "Touch for Quality" Checks. Under the Responsibility of the Team's Quality Technician : By Audit Team : Manufacturing, Engineering, Marketing, By Team Members, or Assembly Line Certified Employees. Permanent Audit.

72 QUALITY MANAGEMENT REDUCE POTENTIAL VARIATION When there are Multiple Ways to Perform Work, and ONLY ONE WAY IS CORRECT. WS Seq. # D D E Overlap Product P/N CONTROL PANELS TWK NBL/NBL-OC / CDT Task Assemble fuse support to frame A 1 screw Install support to control panel - 2 screws TQC Contactor Model Number TQC Fuse Model Number VA Mach Setup D/S Qty I/E SEQUENCE OF EVENTS Required Mach Mach Move D/S Qty I/E Dist. TQC Process I.D. Control Panel Assembly Quality Criteria / Safety Description Left side Size 530 : 3ARR3CT1OV5 Size 536 : 3ARR3CT6A5 Connectors orientation Contactor : 45(C/F)G20AJ Size 530 : 3ARR3CT1OV5 Size 536 : 3ARR3CT6A5 E Install fan capacitor - 1 nut 0.5 Identification : 4µF at the top FINISHED GOODS AUDITS PRODUCT In-PROCESS AUDITS

73 QUALITY MANAGEMENT AUDIT CHECK POINT ELIMINATION ELIMINATE AUDIT CHECK POINT ELIMINATE QUALITY CRITERIA

74 MIED-MODEL LINE DESIGN LAYOUT ON PAPER LFT MIED MODEL Product Synchronization Line Design Product CDT Product CDT Terminal Ass'y Process Map R R CDT CDT Process Panels Ass'y Panels Test Machine R Process R R Terminal R Panels R R R R Panels R Test Ass'y Ass'y R O 22% Machine O 22% 104% 105% 105% 110% 110% 108% 108% 105% 112% 112% 200% 100% 22% 22% Seq. # Product P/N COFFRET ELECTRIQUE TWK NBL/NBL-OC / CDT / / CDT Overlap Sequence of Events Mach D/S DEMAND FLOW TECHNOLOGY Qty I/E Mach Mach D/S Qty I/E Dist. TQC Process I.D. Assemblage Coffret Quality Criteria Task Description Product P/N Process I.D. DEMAND FLOW TECHNOLOGY COFFRET ELECTRIQUE TWK NBL/NBL-OC 0,2 Assemblage Coffret 10 Déballer passe-fils passe-fils droit dans / tôle CDT coffret / / CDT 20 Engager 0,2 30 Fixer contacteur 24V - 1 vis - 1 rondelle - 1 fil de terre Setup 0,6 Move Type 45CG20AJ / 45FG20AJQuality Required Criteria 40 Fixer contacteur 24V - 1 vis - 1 rondelle 0,3 Task A l'opposé du pli. Description 3ARR3CT1OV5 50 Fixer relais de démarrage sur support - 1 vis 0,6 Taille 530 : Type Taille 536 : Type 3ARR3CT6A5 10 Déballer passe-fils 0,2 Relais à l'intérieur du coffret S/Ens. 20 Relais Engager sur tôle passe-fils coffret - 2 droit vis dans tôle coffret 0,2 60 Fixer 0,3 0,5 70 Fixer condensateur 30 Fixer ventilateur contacteur - 1 Ecrou 24V -(Gauche) 1 0,5 A gauche - Marquage Type visible 45CG20AJ 1 vis - 1 rondelle - fil de terre 0,6-4µF / 45FG20AJ 80 Raccorder 40Fil N 7 sur Fixer condensateur contacteur 24V ventilateur - 1 vis -(Gauche) 1 rondelle 0,3 Cosse M/F sur borne Gauche 0,3 90 Raccorder Fil N 7 sur contacteur puissance 0,3 Cosse M/F sur borne A l'opposé Centre/Droite du pli. 50 Fixer relais de démarrage vis Au centre - Marquage Taille visible 530 : Type sur support - 1 0,6 3ARR3CT1OV5 Taille 530 : 35µF Taille 536 : Type 3ARR3CT6A5 100 Fixer condensateur compresseur - 1 Ecrou 0,6 Taille 536 : 40µF 60 Fixer S/Ens. Relais sur tôle coffret - 2 vis 0,3 0,5 Relais à l'intérieur du coffret Côté gauche au S/Ens. 70 Support Fixer borniers condensateur - 2 vis ventilateur - 1 Ecrou (Gauche) 0,5 ras A du gauche pli. - Marquage visible - 4µF 110 Fixer 1,0 120 Raccorder 80Fil N 2 sur Raccorder condensateur Fil N 7 ventilateur 0,3 Borne Inférieure/Gauche Cosse M/F compresseur sur condensateur (Gauche) 0,3 sur borne Gauche 130 Raccorder 90Fil N 2 Raccorder sur bornier Fil puisance N 7 sur contacteur puissance 0,3 Borne Repère "N" Cosse 0,3 M/F sur borne Centre/Droite Au centre - Marquage visible 140 Raccorder Fil N 21 sur bornier puissance 0,3 Borne Repère "L" 150 Raccorder 100Fil N 20 Fixer sur bornier condensateur puissance compresseur Ecrou 0,3 Borne Repère "N" - 1 0,6 Taille 530 : 35µF Taille 536 : 40µF 160 Raccorder Fil N 6 (Rouge) sur bornier puissance 0,3 Borne Repère "N" 170 Raccorder 110Fil de Terre Fixer (V/J) S/Ens. sur Support bornier borniers puissance - 0,3 Borne Repère "Terre" 2 vis 1,0 Côté gauche au ras du pli. 180 Raccorder 120Fil N 4 Raccorder (Noir) sur contacteur Fil N 2 sur puissance condensateur compresseur 0,3 Borne Haut/Supérieur/Gauche. Borne 0,3 Inférieure/Gauche 190 Raccorder 130Fil N 5 (Bleu) Raccorder sur condensateur Fil N 2 sur bornier compresseur puisance 0,3 Borne Droite. Borne Repère 0,3 "N" 200 Evacuer 140 S/Ensemble Raccorder Coffret Fil N 21 sur bornier puissance 0,3 Borne Repère "L" 0,1 0,2 150 Raccorder Fil N 20 sur bornier puissance 0,3 Borne Repère "N" 160 Raccorder Fil N 6 (Rouge) sur bornier puissance 0,3 Borne Repère "N" 170 Raccorder Fil de Terre (V/J) sur bornier puissance 0,3 Borne Repère "Terre" 180 Raccorder Fil N 4 (Noir) sur contacteur puissance 0,3 Borne Haut/Supérieur/Gauche. 190 Raccorder Fil N 5 (Bleu) sur condensateur compresseur 0,3 Borne Droite. 200 Evacuer S/Ensemble Coffret 0,1 0,2 Seq. # Overlap VA Setup Required Move VA Mach D/S Qty I/E Mach Mach D/S Qty I/E Dist. TQC Layout on Paper

75 SUMMARY LEAN FLOW TECHNOLOGY MIED-MODEL LINE DESIGN LFT Line Design Concept. Resources Calculation. Line Design. Daily Resources Management. Flexible Operations. Response Optimization. Operational Definition. "At or Below" TAKT Time Target.

76 LEAN FLOW TECHNOLOGY MIED-MODEL LINE DESIGN SUMMARY Operational Method Sheets. Safety TQC Work Verify. Key Points. Quality Management. Visual Signal. "Touch for Quality". Quality Audits. Layout on Paper.

77 LEAN FLOW TECHNOLOGY QUESTIONS

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