workflow of a garments manufacturing system

it is very important for analyzing the workflow of a manufacturing system.

1. Workflow
Continuous Flow

2. The Traditional Approach
Specialist departments
¾Delay | Transport | Storage
Specialist departments
¾
Long distances
¾Long lead times
¾
Big batches
Operation 2
Operation 3
Operation 1
¾
Big

batches
¾High WIP
¾Hi
g
h cost
Operation 4
g
¾Poor problem
solving & team
spirit
Operation

4
Operation 5
spirit
Operation 6Operation 7
2

3. Dedicated Line Solution
ELIMINATE
Operation 3
ELIMINATE the delays thetransport
Operation 4
Operation 2
O
p
eration 5
Operation 1
the

transport

and storage times
p
Operation 6Operation 7
Operation 6
Operation 1
Operation 6
Operation 5
Operation 7
Operation 2
Operation 1
Operation 2
Operation 7
thanks to parts families and dedicated lines
Operation 4
Operation 6
Operation 1
Operation 1
Operation 5
Operation 2
Operation 5
Operation 7
rather than diffused lines
Operation 4

4. Steps to implement dedicated lines •Define PARTS FAMILIES •Design IDEAL DEDICATED LINES
•Find solutions to ACTUAL CONSTRAINTS
•Find solutions to ORPHAN PARTS •
DesignREALISTICDEDICATEDLINES
•
Design

REALISTIC

DEDICATED

LINES
•Find solutions to MEET THE DEMAND •Implement dedicated lines and
ONE-PIECE FLOW
Operation 6
Operation 1
Operation 6
Operation 5
Operation 7
Operation 1
Operation 2
Operation 7
Operation 4
Operation 6
Operation 1
Operation 2
Operation 1
Operation 5
Operation 2
Operation 5
Operation 7
Operation 4

5. Define parts families based on •High volume (80/20)
Hi h l (80/20)
•
Hi
g
h
va
lue
(80/20)
•Similar by
th f
–
th
e
f
orm
–the material
–
the process sequence the

process

sequence
•Runners, repeaters and strangers

6. Create Process Families
Parts
STEP1
A X X X X
STEP

1
B
C
X
X
X
X
X
X
X
X
Identify the
p
arts and their
D
E
X
X
X
X
X
X
X
X
X
X
X
X
pprocess
F
G
X X
X
X
XX

7. Create Process Families
STEP2
Parts
Identify
STEP

2
A X X X X
Identify similar processes
B
C
X
X
X
X
X
X
X
X
processes
D
E
X
X
X
X
X
X
X
X
X
X
X
X
F
G
X X
X
X
XX

8. Create Process Families
STEP3
Parts
Createparts
STEP

3
A X X X X
Create

parts
family by processes
D X X X X X X E X X X X X X
processes
B X X X X GXXX C X X X X F X X X

9. Analyse the Processes
Machine
Plant:Team:Date:
PARTS/PROCESS MATRIX
Cutter
Auto Single Multi
dl
Drill
Multi
idl
Milling
hi
Wash
Rolling
Gear
Milling
hi
Broach
lth
Process
No
Cutter
lathepurpose
lathe
spin
dl
e
drill
Drill
sp
i
n
dl
e

tapping
mac
hi
netank
Rolling machine
Gear hub
mac
hi
ne
l
a
th
e
Cutting Lathe
cutting
Lathe cut
2
Drilling Cham-
fering
Screw
cuttin
Milling Clean-
ing
Rolling Gear
teeth
cutting
Milling Drilling Debur-
ing
1
2
Part #
Qty
9985M26
9176M25
3
4
9383M42
9522M60
5
6
7
9522M58
9522M50
7 8
9
10

10. Align the processes to optimise families
ELIMINATE
12345
rt A
Op 1 Op 2 Op 3 Op 4 Op 5 Op 6
ELIMINATE
67 8
1
2
3
Par B
COMBINE
1
2
3
45 67
Part B
SIMPLIFY
123
6 5 4
Part C
SIMPLIFY
12345
6
Parts
B & C
P
A,

11. Steps to implement dedicated lines •Define PARTS FAMILIES •Design IDEAL DEDICATED LINES
•Find solutions to
A
CTUAL CONSTRAINTS
•Find solutions to ORPHAN PARTS •
Design
REALISTICDEDICATEDLINES
•
Design

REALISTIC

DEDICATED

LINES
•Find solutions to MEET THE DEMAND •Implement dedicated lines and
ONE-PIECE FLOW

12. Design ideal dedicated lines •One line per parts family
Th h h f i l fi i h d i l di
•
Th
e s
h
ortest pat
h

f
rom raw mater
ia
ls to
fi
n
is
h
e
d
part
inc
lu
di
ng
–every operation –
every function every

function
–support activities
–specialised activities
•The total linkage of all operations and functions required to make a
part (everything is linked by an imaginary conveyor)
•
Dedicated equipment and dedicated workers in a dedicated place
•
Dedicated

equipment

and

dedicated

workers

in

a

dedicated

place
•U shaped flow line
Op 5
Op 4
Op 3
Op 6Op

5
Op

3
Op 2 Op 1
Op 7

13. Find actual constraints
Op 5 Op

5
Op 4
O
p
3
O4
O4
Op 6
p
Op 2
O
p
4
O
p
4
Op 1
Op 7
External operation
•
Supplieroperation
Shared operation •
Expensiveequipment
Supplier

operation
•Immoveable plant/equip
•
Infrequentoperation
Expensive

equipment
•Limited skills
•
Similarcharacteristics
Infrequent

operation
Similar

characteristics
•Close proximity

14. Find solutions to actual constraints
Op 5
Op 4
K
Op 5
Op 4
Op 3
Op 6
Op

4
Op 3 Op 2 Op 1
Op 7
Op 6
Op 2 Op 1
Op 7
Op 4
Op 4
Op 4
Op 4
O3
Op 5
Op 5 Op 6
O
p
3
Op 2 Op 1
Op 7Op

5
External operation
•
JITwithsupplier
Shared operation •
Shareequipment
(shifts schedule)
JIT

with

supplier
•Move cell to plant/equip
•
Moveableequipment
Share

equipment

(shifts
,
schedule)
•Retrain or move the skills
•
Modifyforbothcharacteristics
Moveable

equipment
Modify

for

both

characteristics
•Move together proximity

15. Find solutions to orphan parts •Can a dedicated line adopt them ?
Sh ld j b h li b t d?
•
Sh
ou
ld
a
jo
b
s
h
op
li
ne
b
e crea
t
e
d

?
•Can we use moveable equipment and flexible lines ? •Should they be outsourced ?
•Etc.

16. Design realistic dedicated lines
Fishbone
Line
U Line
L Line
Back to Back
ILine
Lines

17. Steps to implement dedicated lines •Define PARTS FAMILIES •Design IDEAL DEDICATED LINES
•Find solutions to ACTUAL CONSTRAINTS
•Find solutions to ORPHAN PARTS •
DesignREALISTICDEDICATEDLINES
•
Design

REALISTIC

DEDICATED

LINES
•Find solutions to MEET THE DEMAND •Implement dedicated lines and
ONE-PIECE FLOW

18. Batch vs 1 Piece Flow
Batches and delays
One-piece flow

19. Batch vs Flow –(Push vs Pull)
HtHt
5 parts
2h/ t
H
ow
t
o
H
ow
t
o
eliminate eliminate
A
B
C
D
2

h/
par
t

= 10 h
= 10 h = 10 h = 10 h
First
good
part
eliminate eliminate storage, transport and storage, transport and delay delay
wastes ? wastes ?
0.0
10.0
20.0
30.0
32.0
delay delay
wastes

? wastes

?
One One
Batch processing builds large stocks
1 part
2 h/ part
2h
2h
2h
2h
First good part
OneOne Piece Piece
A
B
C
D
2

h
2

h
2

h
2

h
Second
good part
Flow Flow
80
100
0.0
2.0
4.0
6.0
8
.
0
One piece flow eliminates delays and waiting time
2.0
4.0
6.0
8.0
10
.
0

20. The Customer Heartbeat –Takt Time
Time per da
y
Parts per day
Data
420 production minutes per day (8 hours = 480 min - 60 Minute Break) 6 parts per day (120 parts per month - 20 Production Days
==
TAKT
Solution
420 mins /day
6parts/day
70
min/part
6

parts

/day

21. Example Production Line
Required quantity = 6 per day (420 min/day) TAKT i
0
i
TAKT
t
ime =7
0
m
inutes
Cycle time operation 1 = 70 minutes Cycle time operation 2
=
40 minutes
Cycle

time

operation

2

40

minutes
Cycle time operation 3 = 50 minutes
Cycle time operation 4 = 90 minutes
Cycle time operation 5 = 80 minutes
CustomerTakttime
Op 4 Op 5
Part
completed
Customer

Takt

time
Process time of
each o
p
eration
Op 3
p
Raw
material
Op 1Op 2

22. Line Balancing
TAKT: 70 MINUTES = 1 part every 70 minutes
O
p
4 O
p

5
Part
completed
Process capacity of the line
1t 90it
=

1

part

every

70

minutes
p
p
completed
Op 3
=
1
par
t
every
90
m
inu
t
es
Raw
material
Op 1Op 2
0
20
40
60
80
100
120
???
0
20
40
60
80
100
120
Op 1 Op 2
Op 3
Op 4 Op 5
=
set-up time
CYCLE TIME DIAGRAM
=
production time

23. Line Balancing
O
p
4 O
p

5
Part
completed
TAKT: 70 MINUTES = 1 part every 70 minutes
p
p
completed
Op 3
Process capacity of the line
1t 90it
=

1

part

every

70

minutes
Raw
material
Op 1Op 2
0
20
40
60
80
100
120
???
=
1
par
t
every
90
m
inu
t
es
0
20
40
60
80
100
120
Op 1 Op 2
Op 3
Op 4 Op 5
=
set-up time
CYCLE TIME DIAGRAM
=
production time

24. Line Balancing
O
p
4 O
p

5
Part
completed
TAKT: 70 MINUTES = 1 part every 70 minutes
p
p
completed
Op 3
Process capacity of the line
1t 90it
=

1

part

every

70

minutes
Raw
material
Op 1Op 2
0
20
40
60
80
100
120
OK
=
1
par
t
every
90
m
inu
t
es
0
20
40
60
80
100
120
Op 1 Op 2
Op 3
Op 4 Op 5
=
set-up time
CYCLE TIME DIAGRAM
=
production time

25. Summary
ELIMINATE
the delays
Operation 4
Operation 2
Operation 3
Operation 1
1
Set
updedicatedlines
the transport
and storage times
Operation 6
Operation 1
Operation 6
Operation 5
Operation 7
thanks to parts families and dedicated lines
Operation 2
Operation 5
Operation 6Operation 7
1
.
Set
-
up

dedicated

lines
2. Implement 1 piece flow
Operation 1
Operation 2
Operation 7
Operation 1
Operation 5
Operation 2
Operation 5
Operation 7
rather than diffused lines
Operation 4
Operation 4
Operation 6
Operation 1
Batches and delays Batches and delays
3. Balance the line to the
Takt time
One-piece flow One-piece flow
Op 4 Op 5
Part
completed
Op 4 Op 5
Part
completed
TAKT: 70 MINUTES
= 1 part every 70 minutes
Raw
material
Op 1Op 2
Op 3
Raw
material
Op 1Op 2
Op 3 0 20 40 60 80 100 120 0 20 40 60 80 100 120
Op 1
OK
Process capacity of the line
= 1 part every 90 minutes
CC G
Op

1
Op 2
Op 3
Op 4
Op 5
=
set-up time
dti ti
=
set-up time
dti ti
C
Y
C
LE TIME DIA
G
RAM
=
pro
d
uc
ti
on
ti
me
=
pro
d
uc
ti
on
ti
me