Lean Flow Technology Program
Module LFT101US - Lean
Flow Technology ... Definition & Strategy
- Lean Flow Technology - Principles.
- Elimination of Wasting.
- Benefits :
- Market Share, Margin, Pay-Back.
- Traditional Organization Vs. Process Organization.
- Measurable Results.
- 20 Majors Steps.
- Improvement Strategies :
- Quality, Productivity, Inventory Turns.
Abstract
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Module LFT102US - Lean
Flow Technology Data & Quality Management
- Organization.
- Identification of Products.
- Products & Processes Synchronization :
- Value Stream Mapping, Main Line, Feeder Line & Optional Processes, Mixed-Model Product Synchronization.
- Mixed-Model Process Map.
- Demand at Capacity :
- Forecasts Analysis, Projected Vs. Retained Demand at Capacity, Factors influencing Demand.
- Takt-Time :
- Parameters Definition : Dc, H, S.
- Sequence of Events - SOE's :
- Tasks Description - VA Vs. NVA Activities, Setup, Required & Move Times, Labor & Machine Times, Dynamic & Static Setup Times, Safety & Quality Criteria.
- Quality Management :
- Verify & Total Quality Check.
- Quality Improvement :
- Poka-Yoke, 6 Sigma Methodology : Process Capability, SPC, FMEA, ...
- New Products : 100% Lean Flow Technology.
- Employees Involvement :
- Continuous Improvement Teams.
- "Key LFT" Measures :
- Safety, Quality, On-time Delivery, Inventory Turns, Cost & Productivity.
Abstract
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Module LFT103US - Mixed-Model
Line Design
- Lean Flow Technology Line Design Concept :
- Sum of Demands at Capacity, Rework & Scrap Impact, Total Time, Actual Time Weighted.
- Labor & Machine Resources Calculation :
- Line Design, Physical Implementation Consideration, Daily Resources Management.
- Flexible Operations :
- High, Average & Low Times.
- Response Optimization :
- Total Product Cycle Time, Flow Process Lead Time.
- Operational Definition :
- "At or Below Takt Time Target", Quality Management, Employees Flexibility.
- Visual Method Sheets :
- Safety - TQC - Work - Verify, Consistence with Sequence of Events.
- Quality Management :
- ANDON Signal, Touch for Quality, Processes & Products Audits.
- Implementation Layout on Paper.
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Module LFT104US - Material
Flexibility & Velocity
- Inventory Turnover.
- Kanban System :
- Pull Sequences Chains, Kanban Labels.
- Kanban Sizing - "Two-Bin" System :
- Seasonality Analysis, Kanban Daily Rate Definition, Replenishment Interval Time.
- Replenishment Signals :
- Management Lights, "Milk Runs" Strategy.
- Why RIP Stock or Supermarket Locations ?
- Multiple Demands Consolidation.
- Replenishable Vs. Non-Replenishable Kanban ?
- Dual or Multiple-Card Kanban :
- Economical Consideration to Recovery Setup Times.
- Single Level Bills of Material :
- Multi-Level BOM's Elimination, Configured to Order (CTO) Products.
- Keys for Successful Backflush.
- Kanban Analysis.
- Engineering Changes :
- E.C. Implementation on Shop Floor.
Abstract
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Module LFT105US - Unattached
Fabrication Feeder - Dual-Card Kanban
- Material Pull Strategies.
- Unattached Fabrication Feeder Design :
- Product Synchronization, Demand at Capacity, Setup Times Analysis.
- Upstream Demand Management :
- Mixed-Model Sequencing.
- Dual-Card Kanban :
- Run Time to recover Lost Setup, Parts & WIP Quantities Optimization, Machine Resources Availability Optimization.
- Dual-Card Kanban Calculation :
- Minimum Cell Replenishment Quantity, Average Setup Time, RIP Kanban Sizing, Consumption Location Kanban Sizing.
- Parameters Analysis : Takt-Time, K, Kc, Kc Avg, R?, R?QUE, ...
- Dual-Card Kanban Labels.
- Wait-Work Board :
- Wait & Work Side, FIFO Management.
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Module LFT106US - Balance & Flow
- Operational Definition :
- "At or Below" Takt Time Targets to create Balance.
- Flow Balancing Methods :
- Work Content Elimination, Work Moving, Inventory Investment with IPK's Implementation, Additional Resources.
- In-Process Kanban :
- IPK's Sizing, Additional Work Time.
- Balance, Flow & Flexibility :
- U-Cell Design, Low, Nominal & High "Fixed" Capacity Definition, Labor & Machine Resources Calculation.
- Physical Implementation.
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Module LFT107US - Flexible
Employees
- People can only Flex if ...
- Physical Places to Work, Simple & Visual Signals - IPK's.
- Minimum Expectation for Flexing.
- Training - Certification :
- Mastery Program, Cross-Training Board.
- Downstream Demand - Upstream Signal.
- Flex Rules :
- Do I Have a Signal to Work ? Can I Work ? Upstream Flexing, Downstream Flexing - In Direction of Customer Demand.
- Flex Card.
- Flexibility & Benefits for your Associates :
- Variety of Skills, Industrial Injuries Reduction.
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Module LFT108US - Flexible
Employees - Examples
- Minimum Expectation.
- Flex Rules.
- Scenarios :
- Help at Work Station.
- Jump Work Station.
- Quality Place to Help.
- "Bump"& "Holes" in Line.
- Additional Work Station.
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Module LFT109US - Daily
Demand Management
- Any Model, Every Day, "Up or Down" to Demand.
- Demand Time Fence.
- Planning Flex Fences :
- Market Positions & Manufacturing Limits.
- Total Demand :
- ... as a Moving Window.
- Targeted Daily Rate.
- Economic Cost Flexibility.
- Smoothing Time Fence :
- Smoothing Limits.
- Dr or TDr for Flexibility ?
- Volume & Mix Adjustment :
- Example of Daily Demand Management.
- Finished Goods Inventoty & Finished Goods Orders.
- Available To Promise Products & Configured To Order Products.
- Forecasting.
- Daily Demand Management = Daily Based Management + "Best of Breed".
- Linearity.
Abstract
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