Lean Manufacturing Line Demonstration This short PowerPoint presentation is designed to give the reader an example of how a Lean/Pull system operates. It demonstrates how a process, (i.e final assembly) is divided into individual workstations equal to a TAKT time. This causes the work in a process to be balanced where all workstations complete the standard work at the same time. TAKT time is a statement of rate calculated as the available time per day divided by the designed volume of the process. Even though standard work time may vary from process to process and product to product, one complete unit is finished each TAKT time. Because all processes are completed simultaneously, no work in process inventory is accumulated between processes. Customer lead time is the sum of the TAKT times through the critical path processes of the Lean line. Priority changes in customer demand are easily facilitated by rearranging the sequence of demand introduced to the lean line on any given day. Customers rarely order the same volume of demand every day. Matching labor resources to customer demand each day avoids building unsold finished goods inventory. Operator job satisfaction is enhanced by being allowed to be flexible to do different work every day as needed. Please enjoy viewing this presentation. Review as often as necessary to re-enforce your knowledge of how a Lean/Pull system works. Consider how a Lean manufacturing operating system delivers the critical differentials in price, delivery, and quality to give you the leverage you need to capture market share from your competitors. Please contact Dennis Hobbs at Mfg Matters if you have questions about this presentation or any other questions you may have about a Lean business transformation.

 Sequenced Build – First in – First Out at TAKT Rate  Mixed Model Production  Two Bin Material Kanban System  No Work-Center Schedule – Respond to TAKT Signal  Build-to-Order Production – No WIP Build up  Production Sequencing to Match Demand Priority  Output Rate Variation Based On Daily Demand  Flexible Employees Takt 1Takt 2Takt 3Takt 4Takt 5 X S/O SALES ORDER What To Look For

Empty IPK Product 75% complete Product 50% complete Product 25% complete WS 1WS 2 WS3 WS4 Empty Workstation

WS 1WS 2 WS3 WS4 Primary Bin Secondary Bin

WS 1WS 2 WS3 WS4 Is the signal to pull this unit into this Workstation This empty IPK

WS 1WS 2 WS3 WS4 Causing this IPK to be empty Then, this unit is pulled

WS 1WS 2 WS3 WS4 And materials are consumed

WS 1WS 2 WS3 WS4

Product 100% complete

WS 1WS 2 WS3 WS4 Takt 1Takt 2Takt 3Takt 4Takt 5

WS 1WS 2 WS3 WS4 Takt 1Takt 2Takt 3Takt 4Takt 5

WS 1WS 2 WS3 WS4 Takt 1Takt 2Takt 3Takt 4Takt 5 S/O SALES ORDER

WS 1WS 2 WS3 WS4 Takt 1Takt 2Takt 3Takt 4Takt 5 S/O

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Notice that the fourth cycle did not result in a product Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

Takt 1Takt 2Takt 3Takt 4Takt 5 WS 1WS 2 WS3 WS4 S/O Supermarket

 Sequenced Build – First in – First Out at TAKT Rate  Mixed Model Production  Two Bin Material Kanban System  No Work-Center Schedule – Respond to TAKT Signal  Build-to-Order Production – No WIP Build up  Production Sequencing to Match Demand Priority  Output Rate Variation Based On Daily Demand  Flexible Employees Takt 1Takt 2Takt 3Takt 4Takt 5 X S/O SALES ORDER Did You Observe-?