Manufacturing Processes Copyright © Texas Education Agency, 2014. All rights reserved.

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Presentation transcript:

Manufacturing Processes Copyright © Texas Education Agency, All rights reserved.

Manufacturing Process Management Manufacturing industries use different methods to plan and organize the task of production. Copyright © Texas Education Agency, All rights reserved.

Just-in-Time Just-in-Time (JIT) is a manufacturing strategy where inventories are delivered to the process area when needed. This reduces storage costs of excess materials. Copyright © Texas Education Agency, All rights reserved.

Just-in-Time The material inventory supply is reordered when a set number of parts are left on the line. The number is set by how many parts are needed before the new order is received. Copyright © Texas Education Agency, All rights reserved.

Just-in-Time The operators of the line inspect their products and if a problem occurs they may stop the line to correct the problem. This eliminates excessive waste in production. Copyright © Texas Education Agency, All rights reserved.

Six Sigma Six Sigma is a manufacturing process for improving quality to near perfection. Six Sigma strives to achieve no more than 3.4 defects per million opportunities. Copyright © Texas Education Agency, All rights reserved.

Six Sigma Process Define Measure Analyze Copyright © Texas Education Agency, All rights reserved. DefineMeasureAnalyzeImproveControl Improve Control

Define Define the project purpose and scope. Develop a set of production procedures. Determine customer needs. Copyright © Texas Education Agency, All rights reserved.

Measure Develop a set of standards for current process. Determine problem areas of the process. Set goals of production. Copyright © Texas Education Agency, All rights reserved.

Analyze Identify the basic causes of production problems by use of data collected. Determine improvements and analyze the cost of improvements. Copyright © Texas Education Agency, All rights reserved.

Improve Develop improvements for production problems and put them in place. Assess the improvements as to production rate. Copyright © Texas Education Agency, All rights reserved.

Control Check on production rate before and after improvements have been implemented. Track the improvement rate to determine changes in the rate of production. Copyright © Texas Education Agency, All rights reserved.

Management Six Sigma management is described by belt colors: green belts, black belts, master black belts, and champion in the management group. Higher belt colors usually indicate higher pay. In order to get a higher belt, you have to learn more information and accomplish a Six Sigma project. Copyright © Texas Education Agency, All rights reserved.

Types of Six Sigma Projects Reduce waste of products Reduce inventory cost Reduce billing time Increase production rate Increase customer satisfaction Copyright © Texas Education Agency, All rights reserved.

Lean Manufacturing Lean Manufacturing is a system that is based on customer needs. Products are made when orders are placed for them. Any thing that does not add value to the product is waste and is removed from the manufacturing process. Copyright © Texas Education Agency, All rights reserved.

Goals of Lean Manufacturing Decrease the number of process steps Reduce the amount of waste Increase productivity Increase use of capital equipment Copyright © Texas Education Agency, All rights reserved.

Ideas Lean Manufacturing is built on the idea that there are always ways to improve a product, production process, or activity. Ongoing improvement is a driving force in Lean Manufacturing. Improving the customers’ service, reducing waste, product preference, are all important to this type of manufacturing. Copyright © Texas Education Agency, All rights reserved.

5S 5S is a system to organize the workplace to be more productive. Copyright © Texas Education Agency, All rights reserved.

Other Concepts Three other concepts that are also used with 5S are safety, security, and satisfaction. Copyright © Texas Education Agency, All rights reserved.

Sort Divide the inventory, tools, and machines into three groups. Copyright © Texas Education Agency, All rights reserved. Used Daily Used Weekly Never Used After sorting, remove the items that are never used.

Straighten Organize the work area with bins and tool holders. Copyright © Texas Education Agency, All rights reserved.

Shine After removing the clutter keep the area clean and organized. Copyright © Texas Education Agency, All rights reserved.

Standardize Organize all areas the same. All signs, tool holders, and supply bins should be the same throughout the facility. Copyright © Texas Education Agency, All rights reserved.

Sustai n Strive to maintain established procedures within an organized product work area. Copyright © Texas Education Agency, All rights reserved.

Safety Safety is a requirement to having a productive work area. If the area is clean, organized, and efficient, the area and employee will be safe. Copyright © Texas Education Agency, All rights reserved.

Security Protection of employees, supplies, materials, and equipment make a work area more conducive to quality work. Copyright © Texas Education Agency, All rights reserved.

Satisfaction The client being satisfied is only part of satisfaction. The employees should enjoy coming to work. If the employees are satisfied, the quality of the parts manufactured will improve. Copyright © Texas Education Agency, All rights reserved.

Assignment The school wants the flexible metal lab to become more like a manufacturing facility. The lab will be evaluated on implementing one of the manufacturing methods described in the presentation. A team of two students will examine the lab. This team will develop a presentation describing how to implement one of the manufacturing methods. Copyright © Texas Education Agency, All rights reserved.

Please Use These TEKS on Your Slides (1) The student describes the importance of teamwork, leadership, integrity, honesty, work habits, and organizational skills. The student is expected to: (G) use time-management techniques to develop work schedules. (2) The student explores the employability characteristics of a successful worker in the global economy. The student is expected to: (E) communicate effectively with others in the workplace to clarify objectives. Copyright © Texas Education Agency, All rights reserved.