1. 1 Creating Connected Process Flow MHR 5350

2. 2 Just-in-Time  Right part  Right amount  Right time  Right place

3. 3 One-piece FlowOne-piece Flow  Products are processed and moved directly to the next process one piece at a time

4. 4

5. 5 Flow ContinuumFlow Continuum

6. 6

7. 7

8. 8 Tools to Establish One-Piece FlowTools to Establish One-Piece Flow  Pull techniques  Supermarkets/Kanban  Sequenced Pull  Workplace/Cell design  Clearly defined customer/supplier relationships  Visual controls

9. 9

10. 10 Pull  Defined agreement with specified limits pertaining to  Volume of production  Model mix  Sequence of model mix  Dedicated  Controlled

11. 11 Pull Example: Simple ProcessPull Example: Simple Process

12. 12 Pull Example: Three Distinct ModelsPull Example: Three Distinct Models

13. 13 Pull Example: High Product VarietyPull Example: High Product Variety

14. 14

15. 15 Kanban  Signal/Sign/Card  Visual control system used to trigger activity in upstream process  Replenishment for production and material  Usually printed card  Part number/description  Quantity  Location  Picture  Etc.

16. 16 Kanban UsesKanban Uses  Instruction  Self control to prevent overproduction  Visual control  Reduction of managerial cost  Reduction of inventory

17. 17 Kanban AdvantagesKanban Advantages  Processes connected  Eliminates excess inventory  Floor space  Wasted material during model changeover  Boxes/bins/returnables  Potential problem: people

18. 18 Kanban RulesKanban Rules  Downstream process should withdraw the right parts from the upstream process at the right quantity and right time  Upstream process should produce the parts in the quantities withdrawn by the downstream process  Defective products should never be transported to the downstream process  Number of kanbans should be minimized  Kanban can be utilized to adapt to small variation in production volume  Actual quantity of parts in bin/box/pallet must be equal to the quantity on kanban

19. 19 Kanban ExampleKanban Example

20. 20 Kanban ExampleKanban Example

21. 21 Kanban ExampleKanban Example

22. 22 Kanban ExampleKanban Example

23. 23 Think  If some problem occurs in one-piece flow manufacturing then the whole production line stops. Why is that a good thing?

24. 24 Advantages of One-Piece FlowAdvantages of One-Piece Flow  RAPID CONTINUOUS IMPROVEMENT  Build in quality  Increased flexibility  Higher productivity  Decreased floor space  Improved safety  Improved morale  Reduced inventory

25. Project AssignmentProject Assignment  Create current state map (45-60 minutes)  Present current state map 25

27. Questions?