LEAN FLOW TECHNOLOGY

1 lean FLOW TECHNOLOGY . - MODULE LFT106 - BALANCE AND FLOW. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. lean FLOW TECHNOLOGY . BALANCE AND FLOW. PURPOSE. Operational Definition. "At, or Below" TAKT Time Targets to create Balance. Resolve Imbalances. In-Process Kanban. Balance and Flexibility. U-Cell Design. Physical Implementation. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLOW. OVERVIEW. OPERATIONAL DEFINITION. Optimum Flow is achieved by Grouping Tasks "At, or Below" TAKT. Time. When Actual Work Content cannot be Grouped "At or Below" TAKT Time Targets to create Balance = IMBALANCE. Resolve Imbalances : TAKT 1. Eliminate Work Content. NVA. 2. Move Work from one Operation to the Next. OP. OP OP. OP. OP10 20. 20 OP30 OP40 50. 50 OP60 3. Inventory Investment.

2 IPK's. 4. Additional Resources. $$$$$. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLOW. RESOLVE IMBALANCES. NVA NVA. OP10 OP20 OP30 OP40 OP50 OP60 OP10 OP20 OP30 OP40 OP50 OP60. 1 Eliminate Work Content 2 Move Work Elements $ $. OP10 OP20 OP30 OP40 OP50 OP60 OP10 OP20 OP20 OP30 OP40 OP50 OP50 OP60. 3 - IPK's Implementation 4 - Additional Resources lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN IPK's OVERVIEW. Resolving Imbalance. Inventory Investment. Supported with Calculations. Visual Signal to Work or Move. First In First Out Management. OP110. TAKT. OP. OP OP. OP. 20. 20 50. 50. #IPK = 1 !.. OP10 OP30 OP40 OP60. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US.

3 IN-PROCESS KANBAN. FORMULA. IxC. #IPK =. TAKT. I : Imbalance : I=AT-TAKT. C : Cycle of Imbalance : C=H/AT. H : Effective Work Time per Shift. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN. A TYPICAL CASE OF CALCULATION. AT = TAKT = 2 mn. ( ). #IPK's ? #IPK's ? IxC. #IPK = I=AT-TAKT= TAKT C=H/AT=440 IxC #IPK = = #IPK = 20. TAKT 2. lean Flow Consulting $$ ? Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN. CALCULATION IN MIXED-MODEL. AT MAXI = TAKT = 2 mn. ( ). #IPK's ? #IPK's ? IxC. #IPK = I=AT-TAKT= TAKT C=1 (Mixed-Model). IxC #IPK = = #IPK = 1. TAKT 2. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN. BETWEEN PROCESSES FORMULA. Cast Spray Kiln Pack #IPK = A x B.

4 Between Processes : A : Shift Difference. B : Dc per Shift Longer Process. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN. A TYPICAL CASE OF CALCULATION. #IPK's ? Cast Spray Kiln Pack Dc : 300 300 300 300. Shifts : 2 1 3 2. Dc per Shift : 150 300 100 150. Compare Side by Side Processes. Example between Cast and Spray Processes : Calculate the Shift Difference between Processes. 2 1=1. Select the Dc for Process with Greater Number of Shifts. Cast Process : Dc per Shift = 150. #IPK's = A (Shift Difference) x B (Dc per Shift Longer Process). #IPK's = 1 x 150 = 150. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. IN-PROCESS KANBAN. WET LINE. Additional Work Time to : Preserve a "Wet Line" : AFTER EACH PRODUCTION DAY. Hold Production Flow in Balanced.

5 Calculate Additional Resources. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. ADDITIONAL WORK AROUND IPK's A TYPICAL CASE OF . AT = Additional Work = #IPK x AT. #IPK = 5. #IPK : Size of IPK's. TAKT = 8 AT : Actual Time. Additional Work = 5 x RESOURCES FOR ADDITIONAL WORK = 44 min. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLOW. U-SHAPED CELLS. IPK's IPK's IPK's IPK's 15T Final Welding Test Press Assembly First Step of Improvement : U-SHAPED CELLS. Several Operations by Employee. 15T. Space Floor Saving. Press Welding Create Balance. Cells designed for Flexibility. Test Improve : Machine Utilization. Labor Productivity. Final Final Operational Cycle Time. Ass'y 1 Ass'y 2. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US.

6 BALANCE AND FLEXIBILITY. TAKT TIME. Wished Flexibility : -20% Nominal +20%. Demand at Capacity - Dc : 22 28 34. TAKT Time (mn) : 15 Effective Work Time per Shift (mn) : 420. Number of Shift(s) : 1. Nominal Dc : 28 TAKT Time (mn) = 15. Low Dc : 22 TAKT Time (mn) = lean Flow Consulting High Dc : 34 TAKT Time (mn) = Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. RESOURCES CALCULATION. Wished Flexibility : -20% Nominal +20%. Demand at Capacity - Dc : 22 28 34. TAKT Time (mn) : 15 #OP Theoretical : #OP Effective : 3 4 5. Total Time from SOE's (mn) : # Operations : #OP (Dc) = / 15 = ??? #OP (Dc-20%) = / = #OP (Dc+20%) = / = lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. CORRECTED CAPACITY. Wished Flexibility : -20% Nominal +20%. Demand at Capacity - Dc : 22 28 34.

7 TAKT Time (mn) : 15 #OP Theoretical : #OP Effective : 3 4 5. Corrected Capacity : 23 30 38. Total Time from SOE's (mn) : Effective Work Time per Shift (mn) : 420. #OP Theoretical : 4 Capacity / Day = 420 x 4 / = 30. #OP Theoretical : 3 Capacity / Day = 420 x 3 / = 23. lean Flow Consulting #OP Theoretical : 5 Capacity / Day = 420 x 5 / = 38. Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. CORRECTED FLEXIBILITY. Wished Flexibility : -20% Nominal +20%. Demand at Capacity - Dc : 22 28 34. TAKT Time (mn) : 15 #OP Theoretical : #OP Effective : 3 4 5. Corrected Capacity : 23 30 38. Corrected TAKT Time (mn) : 14 11. -23% Nominal +26%. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. LOW CAPACITY DEFINITION. T 358 Bender XX 7. Special T 258 Bender Bender T 56.

8 45. 4 5 T 45/7 T 77 T 78. TX. AZ5 Welding Spot Test Test 3. A 4 5 6 4 5. T 96 Test 2. B C. 1 6 1 2 3 1 2 3 6. Test T 85 Machine T 1232. T 89 T 91 Control T 86. H. Test 700 T 45 Final Test Welding Welding Machine T 6222 T 6224 Panel Test lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. NOMINAL CAPACITY DEFINITION. T 358 Bender XX 7. Special T 258 Bender Bender T 56. 45. 4 5 T 45/7 T 77 T 78. TX. AZ5 Welding Spot Test Test 3. A 5 1 2 2 3. T 96 Test 2. B C D. 1 1 2 3 4 3 4 1 4. Test T 85 Machine T 1232. T 89 T 91 Control T 86. H. Test 700 T 45 Final Test Welding Welding Machine T 6222 T 6224 Panel Test lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. HIGH CAPACITY DEFINITION. T 358 Bender XX 7. Special T 258 Bender Bender T 56.

9 45. 4 T 45/7 T 77 T 78. TX. AZ5 Welding Spot Test Test 1. 3. A 3 4 1 2 3. T 96 Test 2. B C D E. 1 2 3 1 2 2 3 1 4. Test T 85 Machine T 1232. T 89 T 91 Control T 86. H. Test 700 T 45 Final Test Welding Welding Machine T 6222 T 6224 Panel Test lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. BALANCE AND FLEXIBILITY. FLEXIBLE PRODUCTION SYSTEM. #OP based on Customer Demands. T 358 Bender XX 7. Special T 258 Bender Bender T 56. 45. 4 T 45/7 T 77 T 78. TX. AZ5 Welding Spot Test Test 1. 3. A 3 4 1 2 3. T 96 Test 2. B B C C. 1 2 3 1 2 2 3 1 4. Test T 85 Machine T 1232. T 89 T 91 Control T 86. H. Test 700 T 45 Final Test Welding Welding Machine T 6222 T 6224 Panel Test lean Flow Consulting FLEX ! FLEX ! Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. lean FLOW TECHNOLOGY . TIMES IN LFT. TAKT Time.

10 Volume driven Time Targets. By Process. Actual Times. AT. From the Sequences of Events. SOE's. Operations. Work Grouped within a TAKT Time Target. Balance. Between Actual Time at Operation (AT) and TAKT Time, Not Between Operations. lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. MIXED-MODEL LINE DESIGN. PHYSICAL IMPLEMENTATION. Demand at Capacity. Operational Definition. TAKT Time. Staffing. Daily Rate. Effective Work Hours. Kanban Sizes. Number of Shifts. Method Sheets. Replenishment Intervals. Sequence of Events. IPK's Sizes. Sequence Lists. Which Should Change Every Day ? lean Flow Consulting Creating World-Class lean Enterprise Copyright 2001-2008 Philippe Magnier All rights reserved Module LFT106 - Release US. MIXED-MODEL LINE DESIGN. PHYSICAL IMPLEMENTATION. OP01 OP02 OP03 OP04 OP05 OP06 OP07 OP08. OP12. OP21. RIP03 OP32 OP31. #KB's =. OP11. RIP01.