It's not unusual for a Line Design to have optional processes and optional subassemblies. In this video we'll take a look at some of the options available to you as a designer to connect these option processes to their downstream customers in the work flow.
We are big fans of Simulation Modeling for lean designs, especially now that it is a lot easier to build models with tools like the Lean Design Simulator. We’re not alone…I heard from a simulation industry insider that Toyota has embraced modeling in a big way in the last few years.
Remember that your goal is to deliver a Value Stream design that is extraordinarily lean to begin with, and one that does not require a lot of Kaizen tweaking afterwards.
The balance between the number of shifts in your line design comes down to resource utilization versus operations costs. In a One-Shift scenario the fixed asset utilization is the lowest. Only 1/3 of the capacity of the fixed assets are being utilized. For 2/3s of the day, they sit idle. A one-shift line design requires more floor space than any of the alternatives. On the plus side, you would normally find most support activities available during the first shift. Plus, working only one shift allows for the most additional capacity for growth. A one-shift line design tends to be the preferred path for high growth industries or factories with low fixed asset investment.
Takt Time or Takt is a German word that refers to the timing or tempo of a musical passage. Other ways to think of this are the beat or the rate. It is both calculable and measurable. For your Mixed Model line, Takt is the line's formulated production rate. This rate is calculated and is a design parameter for the line.
In this lesson we'll review the subject of Inventory Record Accuracy, and how to measure it.
Value Stream Mapping (VSM) is a common assessment tool in the world of Lean Manufacturing. The idea is straightforward: create a flow chart of the way things are today for a specific workflow, brainstorm and apply “lean thinking” to possible improvements and show what the Value Stream would look like if the improvement ideas were implemented. The first map is what is called the Current State, the improvement ideas are “Kaizen Bursts”, and the improved map is the Future State. What’s not to like?