Airbus Production System Training Pack Training Pack Airbus Production System Module: Standard Work Element: Standard in Process Stock Module: Standard Work Element: Standard in Process Stock

Aims & Objectives Target Audience :Operations, Manufacturing Engineering. Purpose of Module : To gain an understanding of Standard In Process Stock (SIPS) Aims & Objectives : Define SIPS To Learn how to calculate SIPS Gain an understanding of how SIPS fits into Standardised Work To raise awareness of how SIPS can eliminate Waste and support flow Page 3

Welcome to the Standard In Process Stock Session Definition Best combination of man and machine to achieve output with minimum labour, space, inventory and equipment. Objectives To establish and clarify the guidelines for manufacturing Quality, Quantity, Manpower, Inventory, and Safety Provides a tool for Kaizen SIPS is part of Standard work. To understand SIPS we must first have a VERY BRIEF overview of the elements of Standard Work. Standard work is the term used to describe the optimum combination of human work, machine work and materials. Standard work ensures that tasks are performed following best current practice with the minimum of waste. In Standard Work all operators should perform the same task in the same repeatable way. Where there is no standard there can be no KAIZEN Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 5

Elements of Standard Work Flexible Work Design Flexible Work Design Line Balancing Standard Work Instruction Sheets Takt time/ Cycle time Standard In Process Stock Standard Work Standard Work Line Balance Standard Operations (SWIS.) Takt Time Standard In-Process Stock Standard work has 5 key elements. LINE BALANCING is:- The even distribution of human work across a production area. The work is balanced to ensure that know one works in conditions of waste, overburden or unevenness. STANDARD WORK INSTRUCTION SHEETS are:- Documents describing the best combination of man, material, and method to perform a given task. These cover a task key “knack” points, safety points, quality points and ergonomic points. TAKT TIME is:- Time Available/Customer demand. (The pace of production) CYCLE TIME is:- Takt time x .95 (The time taken to complete one cycle of a work process) SIPS is:- Will cover during presentation Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 6

What is Standard in Process Stock? Standard minimum number of pieces of In Process Stock required to run each activity (Machine operation) on demand Automatic operations require Standard In Process Stock to enable the worker to be separated from the automatic cycle No standard in process stock is required at manual operations The minimum number of in-process parts required to ensure the smooth operation of work without the Waste of waiting The key thing to understand is the term IN PROCESS. This is not inventory. SIPS enable machines to run on demand, and minimises waiting waste within work sequence. SIPS ensure that the system is PRIMED with the minimum level of stock. S.I.P.S. considers? Takt Time Work sequence Material flow Process (Auto / manual) Number of operators Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 7

Standard in Process Stock F.G. R.M. B A All manual operations: SIPS = 0 C D E F.G. R.M. B A All automatic operations: SIPS = 5 Re-enforce the fact that manual operation do not require SIPS (NB, The arrows denote operator movement between machines. SIPS allow the operator to keep moving. No SIPS = Waiting) SIPS is required at any machine with an automatic cycle, manual operations are balanced to takt Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 8

How do we Calculate Standard in Process Stock? Standard in Process Stock (SIPS) can be calculated using the following equation. SIPS = Machine Cycle Time Takt Time Work through an eg. If it takes 50mins to heat treat components, and the takt time is 25 mins, SIPS will equal 2. SIPS need to be calculated for each machine with an automatic cycle within a production cell. Material will flow smoothly within the process with minimal stock. The build process will include activities of transportation by different operators in the same sequence. The work sequence is determined by the use of a work instruction sheet based on the capacity of the process. Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 9

C D B E A F.G. R.M. Worked Example CT-30min CT-36 CT-60min Machine CT-30min D Machine B Machine CT-36 CT-60min Takt time = 6 mins SIPS = ? E A Machine Manual CT-42min F.G. R.M. Work through the SIPS for machines A, B & C (Refer group to slide 9 for calculation) SIPS = Machine Cycle Time / Takt Time Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 10

C D B E A F.G. R.M. Worked Example E CT-30min Machine CT-30min Therefore with SIPS and Balanced manual ops, a part will move every 6 mins D Machine B Machine CT-36 CT-60min Takt time = 6 mins 6 min E Time E A Machine Manual CT-42min F.G. R.M. Work through the SIPS for machines A, B & C (Refer to slide 9 for calculation) CLICK MOUSE- 7 SIPS for A (Appear) CLICK MOUSE- 10 SIPS for B (Appear) CLICK MOUSE- 5 SIPS for C (Appear) CLICK MOUSE- 6 SIPS for D (Appear) Ask how the group think the manual operations will be defined? CLICK MOUSE- Line Balance (Appear) CLICK MOUSE- Arrows and Statement (Appear) Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 11

Review of Standard in Process Stock Incorrect Standard In-Process Stock causes waste in the sequence. Key points to review are:- Is the quantity set for standard in-process stock correct? Is the quantity set for standard in-process stock strictly observed? Is the stock in the process really necessary? If the stock is necessary, is it at the minimum quantity? IDEAS:- Only carry standard in-process stock required Locate display board at location requiring standard in-process stock, and display the quantity standard Incorrect SIPS causes waste in the sequence. Once SIPS are calculated you must keep checking the process to ensure that it is working smoothly with minimum SIPS. Make adjustments were necessary and then Standardise. Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Page 12

Aims & Objectives Target Audience :Operations, Manufacturing Engineering. Purpose of Module : To gain an understanding of Standard In Process Stock (SIPS) Aims & Objectives : Define SIPS To Learn how to calculate SIPS Gain an understanding of how SIPS fits into Standardised Work To raise awareness of how SIPS can eliminate Waste and support flow Did we Succeed ? Did we? Page 13