Business Basics
Home Page


Who is Bill Gaw?
And why should we
listen to him?

 

lean manufacturing principles and techniques training

Need a training tool that transforms MRP supporter into LEAN-MRP advocates?
LEAN-MRP Simulation Game-Plus

Lean Certification at your place and at
your pace with a "pay-as-you-go" plan.
Lean Manufacturing Certification

10 Steps to Lean Manufacturing Success
Step  8 of 10


Get Bill Gaw's Lean Manufacturing Book
$15.00 Click Here

 


privacy policy

987

760-945-5596

Mfg. Training Options:

Lean Manufacturing Transformation

LEAN-MRP Simulation Exercises

Lean Manufacturing Certification Program

Lean Manufacturing
on-site Seminars

Inventory Management
Training Program

Lean Manufacturing, PowerPoint, 8-CD, Training Library

Lean Management PowerPoint Training Modules

Lean Management PowerPoint Training

Lean Manufacturing Assessment and Improvement Plan

Kaizen Training
(On-site Program)

ISO 9001-2008 Compliance and/or Registration

Strategic Planning Training Program

Manufacturing Perform-ance Management Training Program

Thinking-Outside-
the-Box Workshop

Lean Manufacturing Articles

STEP EIGHT-PULL PRODUCTION

    The objective of Step Eight is to have material "glide along smoothly" to meet customer demand. Production is pulled through the factory one unit at a time at a rate determined by customer demand. Material movement is based on actual consumption with a pull signal being generated and communicated to the next operation. In manufacturing cell, production begins only when pre­scribed parts are available for each operation. Running minus parts only adds cost and creates the risk of increased defects. U-shaped lines or cells are utilized with equipment positioned in a logical order. The primary objective of the U-shaped design is to have product en­ter and exit at the same position. Ideally one unit enters a manufacturing cell as a completed united exits the cell. The U-shaped cell minimizes material movement and storage. Moving, storing, or handling without process­ing a part are non-value-added operations that add cost, and Figure 1 shows how a carpet manufacturer designed a U-shaped line to reduce these non-value costs.

The U-shaped cell allows the use of successive verification (an operator verifies the work of the previous operation). Successive verification is used in addition to poka-yoke devices to prevent obvious errors from moving further down a manufacturing cell and foster communication and teamwork. Job rotation is used throughout the day or week to ensure trained employees maintain proficiency in each job within a manufac­turing cell or production line. Job rotation can also reduce the occurrence of repetitive motion syndrome. The cross-trained employees within a manufacturing cell or line provide the flexibility of moving people within or between cells to meet fluctuations in demand. Work­ers demonstrate the ability to respond to changes in job content, cycle time, and job assignments so that variations in demand are met quickly and effectively.

Another benefit of Step Eight in lean manufacturing is the reduction of floor space required to produce a product. A data communication supplier reduced required floor space by 45 percent after implementing lean concepts including U-shaped manufacturing cells. Op­erations that were completed on two different floors were consolidated onto the first floor while output in­creased by over 50 percent. A control valve manufacturer who implemented lean and group technology reduced component travel distance from almost 2 miles to 20 feet for the machining operations. By consolidating operations and reducing work in process inventories, the manufacturer of farm equipment was able to reduce required floor space over 40 percent. Savings in floor space have ranged from 30 to 70 percent after implementing lean concepts. In more than one case, companies were able to forgo or elimi­nate the need for expansion by freeing up space in an existing site.

To Be Continued

For balance of this article, click on the below link:

Lean Manufacturing Articles and click on Series 14


   Increase Your Knowledge... Stay Connected
Join our 15,000 plus MBBP
Bulletin Subscribers

To stay current on Lean Manufacturing principles and techniques, subscribe to our Manufacturing Basics and Best Practices Bulletin (MBBP) and we'll send you our 10-PowerPoint-Plus, Lean Manufacturing, Mini-Modules. (All at no cost of course.)

  Your personal information will never be disclosed to any third party.

First Name:
Your E-Mail:

Here's what one of our 13,000 plus subscribers wrote about the MBBP Newsletter:

"Great manufacturing articles. Thanks for the insights. I often share portions of your articles with my staff and they too enjoy them and fine aspects where they can integrate points into their individual areas of responsibilities. Thanks again."

               Kerry B. Stephenson. President. KALCO Lighting, LLC


"Back to Basics" Training for anyone ... anywhere ... anytime

Business Basics, LLC
6003 Dassia Way, Oceanside, CA 92056
West Coast: 760-945-5596 

© 2001-2013 Business Basics, LLC