Process One Manufacturing Solutions

Link to whiteboard activity Demonstration Link to whiteboard activity Invite a student up to write on the board

Process One Manufacturing Solutions Understanding process engineering

John Hayter Industry background Tool fitter and mechanical engineer/design. 38 years experience in the manufacturing industry in Australia, South America, Africa, Asia Pacific, Europe and North America. Process engineer / Manager Supplier quality Assurance engineer Product development engineer Production Engineer Project manager.

Greg Vincent Industry background Fitter and turner, tool maker, and production technician. 35 years of experience in the manufacturing industry in Australia, South Africa, Asia Pacific, Japan and Thailand. Tool maker/maintenance fitter Engine plant and machining Production supervision Apprentice master (training) Production management Manufacturing manager for Asia Pacific Manufacturing engineering manager for Asia Pacific and South Africa.

Objectives of session This course is designed to increase the awareness and understanding of processes: How a process is broken into process steps Analysing process steps in manufacturing Identifying ways to improve a process.

Topics to be covered Part one: Defining a process Measure a process Analyse a process Standard operating procedures (SOP) Standard times Part two: Calculating Takt time Part three: Process improvements.

What is a process? Definition A process is a sequence of actions that achieve a result. Industrial processes are procedures involving mechanical steps to manufacture a product. Production of a specific product may involve more than one type of process.

Link to whiteboard activity Demonstration Link to whiteboard activity Invite a student up to write on the board

Writing on the whiteboard Process steps Verbal Instruction given Subject thinks about instruction Subject gets up from seat Subject Moves to pick up pen Recognise pen and orientate Subject picks up pen Move to whiteboard Take lid off pen and orientate Move pen to board and write name Put lid back on pen Return pen to original location Redirect movement Walk back to chair Sit down.

Coffee exercise Write down the steps required to make a cup of coffee. Use the sheet provided. Instruct students to write down how to make a coffee Go through coffee making steps with class collectively and compare results

Process variations There are a variety of different types of coffee: Percolated coffee Plunger coffee Instant coffee Black coffee Cold coffee No sugar Sweetener White coffee Strong coffee With sugar …one or two spoons

Communicating instructions A precise specification for making coffee Hot coffee in a medium sized cup 250ml A level teaspoon of Nescafe blend 43 coffee Full cream milk 20ml 2 level teaspoons of white sugar Boiling water 200ml Stirred - six rotations with a teaspoon.

Standard operating procedures Consistency in process

Standard operating procedures What is a standard operating procedure? A Standard operating procedure (SOP) is designed to communicate the precise specification and sequence of events for manufacturing. It is essential for producing reliable consistent products.

Activity Using the specification provided, write up a standard operating procedure for making coffee. Use the sheet provided.

Communicating instructions A precise specification for making coffee Hot coffee in a medium sized cup 250ml A level teaspoon of Nescafe blend 43 coffee Full cream milk 20ml 2 level teaspoons of white sugar Boiling water 200ml Stirred - six rotations with a teaspoon.

Standard operating procedure List of Process steps for making coffee Check and fill kettle Turn kettle on Boil water Move to cupboard Collect coffee and sugar containers and cup Place coffee and sugar containers and cup on work bench Locate spoon and put on work bench Move to coffee container Remove lid from coffee container Take one spoon of coffee and place in cup Move to sugar container Remove lid from sugar container Add two level teaspoons of sugar to the cup Add boiling water to cup Collect milk from fridge and add 20ml to cup Return milk to the fridge Stir with spoon minimum six rotations Replace lids and return coffee and sugar containers to cupboard Special note: Milk must be kept in fridge at all times.

Summary of standard operating procedures Recognised finite process steps Identified process variation Defined a clear specification Understand why a specification is required Understand standard operating procedures.

Standard times

Standard times Definition Standard times are used to measured how long each element/step of a process takes to complete. The time of each process step, links to the cost of manufacture. Standard time is used to estimate capacity and labour cost.

Process flow with standard times

Standard times for coffee making Calculating standard times to make a coffee based on the specification. Total time calculated from the 18 process steps = 120 secs per cup of coffee Labour is costed at $1.00 per minute = $2.00 per cup to manufacture If the process remains the same, the maximum manufacturing capacity = 30 cups of coffee per hour.

Standard time development in industry

Industry sample of standard times Group Discipline Item Description Time/ Secs Clamping / Tooling Open / close hand clamp 2.5 Actuation Open / close dump unit 3   Location pin on / off 2 Press buttons Process time / sequence (Clamps ON / Clamps OFF) (2 + 2 = 4 secs)

Purpose of standard times Standard times are measured against the actual time man and machine takes to complete a process. If there are time deviations over standard times the operation cycle time needs to be assessed.

Standard time Standard time is unique to the: equipment operation man power environment.

Standard performance Definition The output rate of a qualified worker without over-exertion, as an average over the working day/shift. Providing that the operator: is trained in the operation understands and adheres to the procedures is motivated applies themselves to their work.

Cycle time Definition The total time taken to complete the combination of elements or steps which make up the work cycle (process steps). The total operation time is broken down into: Manual labour Machine operation.

Actual time Definition The observed time taken to perform an element or combination of elements of work, obtained by direct measurement. Actual times of process steps that are over the given takt time and/or standard time, are assessed to identify where improvements can be made to decrease cycle times.

Elements of a process Spot welding The expectation is one spot weld is completed in the standard time of 4 seconds. Hold position 1 second Squeeze position 1 second Apply spot weld/current 1 second Hold/cool position 1 second.

Estimating Example To apply 100 weld spots to a plate at 4 seconds each (regardless of gun positioning times) should equal 400 seconds of spot welding only. Man and machine time need to be assessed to confirm the overall process time meets customer requirements.

Equipment element Machine element Standard time Actual time Hold position 1 second Apply spot weld Squeeze position Hold/cool position Total time 4 seconds In this example the machine times meet the process requirements.

Human element Operator element Standard time Actual time Position gun 1 second 1.5 seconds Squeeze trigger 0.8 seconds Remove 1.7 seconds Total time 3 seconds 4 seconds In this example the actual time does not meet the process requirements. The actual time is one second longer than the standard time which will affect the number of units produced over a shift.

Cycle time results Element Standard time Actual time Machine 4 seconds Operator 3 seconds Total time 7 seconds 8 seconds To reduce cycle time the operator movements and work environment are assessed to identify where improvements can be made. Time deviations may occur due to one operator being slower than another.

Standard performance criteria When assessing standard performance of operators, consider the following: Physical strength/size Stamina over an 8 hour shift Is the operator trained Operators level of understanding Ergonomics Environment Age (maintaining an efficient pace) Selecting the right person for the job.

Other time deviations Unplanned inefficiencies Some time variations are outside the operators control. These can include: Variation in the quality of material used Changes in operating efficiency of tools or equipment Changes in methods or conditions of the operation Variation in the operators focused attention that is required to perform certain elements Change in temperature, lighting or environment.

Summary of standard times Each process step can be measured against time Identify the differences between man and machine elements in a process Compare the cycle times against standard times Analyse performance criteria Identify any timing issues. Questions…

Part two Takt time 39

Takt is a German word which refers to the beat of music. What is Takt? Takt is a German word which refers to the beat of music. During the 1930's, Germany and Japan were part of the Axis. German engineers helped organise the Japanese aircraft industry. After the war, Toyota picked up the word and used it in the Toyota Production System.

What is TAKT time? Definition Takt time is the maximum time allowed to produce a product to meet customer requirements. Production rate is expected to fall within a pace or cycle that is better than or equal to takt time.

Details required to calculate Takt time How many units need to be produced per year? 22000 units per year How many days are worked per year? 220 days worked per year How many shifts are worked per day? 2 shifts per day How many hours are worked per shift? 8 hours per shift

Takt calculation formula Number of units per annum 22000 Number of days worked 220 = 100 units per day Number of minutes worked per day 960 (2 shifts) Number of units required per day 100 = 9.6 mins per unit takt time 1 unit every 9.6 minutes = 6.25 units per hour Factory efficiency has not been used in this calculation.

Calculation of takt time It is important to compare takt time information with how many units your workplace can manufacture against your current factory set up. Unit numbers changed to 7 only complete units rounded up

Efficiency formula Efficiency = Actual number of hours worked per shift (minus breaks etc). Total number hours worked per shift less time for: breaks fatigue maintenance activities other activities.

Work day inefficiency Planned inefficiencies 8 hours at work per day less: 2 x 15 minute (am/pm) 10 minutes cleaning 10 minutes maintenance activity 5 minute fatigue factor. = 8 hours – 55 minutes Unplanned inefficiencies are also a factor. Discuss unplanned inefficiencies acquired from historical data

Work day efficiency calculation = 480 mins work time per shift – 55 mins down time = 425 mins available work time per shift 425 minutes x 2 shifts = 850 minutes work time over 2 shifts Therefore efficiency in this example is 850 960 x 100 = 88.5% The current industry standard is approximately 85%. 85 mins = smoko, lunch, breaks

Efficiency relative to TAKT time Consider the following: = 6.25 units per hour required at 100% efficiency Incorporating the rate of efficiency 6.25 88.5% efficiency = 5.53 units per hour Only 5.53 units per hour can be manufactured.

Process efficiencies To meet the output required per day: 5.53 units/hour at 88.5% efficiency = 88 units per day Takt time required is 6.25 units per hour = 100 units per day With 88.5% efficiency production is now 12 units less than required for the client per day. Options now need to be considered to adjust the factory manufacturing capacity.

Questions… Summary Understand what Takt time means. Identify information used to calculate Takt time. How to calculate Takt time. Calculate inefficiencies. Calculated manufacturing capacity. Questions…

Part three Improving a process 51

Link to Toast Kaizen video Video demonstration Link to Toast Kaizen video Invite a student up to write on the board 52

Areas to identify Information required to improve a process: Understand the process and process steps Map out the process. Measure a process using standard times Time and motion study of process operations including distances moved by operators and materials. Introduce process controls Ensure the SOP is current and all quality needs are defined. Look at plant layout Work in progress, bottleneck operations, safety breeches, material handling requirements, visibility, ergonomics.

Improving performance Questions to ask can include: Is there another way to perform the operation and still maintain the quality? Have the conditions changed since the operation was added to the process? Could the operation be combined with a previous or a subsequent operation? Would changing the sequence improve the operation? Can the materials be moved closer to the work station to reduce material handling time? If the operation is modified, will subsequent operations be affected?

Improving performance A manufacturing process needs to be designed simply for the majority of workers to understand what is required. The process must be user-friendly. Use operators who are physically suited to the work. Increase operator skills and understanding through training.

Process improvement demonstration Link to floor plan activity Invite a student up to write on the board 56

Summary of improving processes Optimisation of labour Reduced the amount of floor space used Improved transfer of parts Improved machine process capability (cycle time) Meet material handling and specification requirements. Questions…

Process improvement exercise How can you improve the coffee making process?

Example A time and motion study is a way for business to identify ways to reduce the number of motions in performing a task to increase productivity. The best known experiment involved bricklaying. By carefully looking at a bricklayer's job, Frank Gilbreth: reduced the number of motions in laying a brick from 18 to 5.

Process improvement exercise Reflect on processes within your work place. Identify one process in your work place that can be improved. How could you improve this process? Write your answers on the page provided.

Thank you for taking part in today's session. End Thank you for taking part in today's session.