MIXED-MODEL LINE DESIGN LINE DESIGN CALCULATION FLOW

Transcription

1 MIED-MODEL LINE DESIGN LINE DESIGN CALCULATION FLOW Product CDT CDT Dc s Required / Optional % Dc Product CDT CDT Yield Process Terminal Ass'y Ass'y Process ine Terminal Scrap R R R Product Ass'y Ass'y R R R R Process ine R R Terminal R 104% 105% 105% R 2 R Product O 22% Ass'y O 22% Ass'y CDT 110% 110% 108% 108% ine 105% 112% 112% 5% 1% 2% CDT % 100% 22% 22% CDT 2% 2% 3% 3% 3% 1% 4% CDT 5% 2% 5% 10% Actual Time from SOE s Product CDT CDT Terminal Ass'y Process Ass'y ine R R R LFT Σ Dc TAKT ATw Resources

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

3 ALL FACTORS ROLLED PROCESS MAP OVERVIEW Product CDT CDT CDT FRU111 L101 Brazing 109% 218% 218% 218% 109% 210% 102% Process L101 ine 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.

4 PROCESS MAP TIME OVERVIEW Product CDT CDT CDT FRU111 L101 Brazing Process L101 ine 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. ine Time. Other Definition of Mixed-Model Process Map with : ONE LABOR TOTAL TIME, ONE MACHINE TOTAL TIME, by Product and Process Relationship.

5 DAILY DEMAND MANAGEMENT OVERVIEW LINE DESIGN : ONCE TO Dc ATw TAKT = RESOURCES Dc ine 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)

6 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

7 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) ine Maximum Daily Rate (Dr) (Dr/Dc) % 59% 94% 147% 70% 71% ine Utilization Rate 50% 75% 125% 35% 55%? New Mixed-Model Line for Family of Products 40A with 3 ines : L01-L02-L03 Products 40A % 83% New Mixed-Model Line for Family of Products 63A with 2 ines : L04-L05 Products 63A % 45% We can Increase the Utilization Rate, with fewer ines, by Improving our Response Capability. TPM Recommendation : Dc = 85% of ine Capacity.

8 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

9 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

10 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 40 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 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 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

11 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 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 Evacuate Sub-Assembly control panel to IPK 0.1 D E Set screwing machine - Check Torque S 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 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

12 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

13 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

14 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.

15 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.

16 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.

17 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 Setup D/S Qty I/E SEQUENCE OF EVENTS Required 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