Creating Mixed Model Value Streams Practical Lean Techniques for Building to Demand 2nd Edition by Kevin Duggan ISBN 1439868433 978-1439868430

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Product details:

ISBN 10: 1439868433
ISBN 13: 978-1439868430
Author: Kevin Duggan

Following in the footsteps of its bestselling predecessor, Kevin J. Duggan, an executive mentor and recognized authority on Lean and Operational Excellence, draws on more than 10 years of experience and learning to provide Creating Mixed Model Value Streams, Second Edition. This second edition takes a step-by-step approach to implementing Lean in complex environments and describes which Lean techniques to use when faced with difficult situations―including high product mix, scheduling problems, shared resources, and unstable customer demand. In addition to a new section on handling shared resources to support mixed model production, the second edition:

• Contains updates to sections on mixed model value streams
• Introduces new information on constructing product family matrices
• Expands on the concept of takt in mixed models
• Provides additional insights on existing mixed model concepts, such as determining product family, takt capability, and heijunka (load level scheduling)
• Presents new concepts on sequencing work, such as offset scheduling and sequenced first-in, first-out (FIFO) lanes

Illustrated with a case study based on actual experience as well as downloadable resources with helpful tools, the book walks readers through the reasoning the author has used with great success in practice. It delves beyond the basics of value stream mapping to explain how to create future states in a manufacturing environment characterized by multiple products, varying cycle times, and changing demand. Demonstrating advanced techniques for creating flow through shared resources, it also considers the concept of a guaranteed turnaround time for the shared resource.

The Downloadable Resources Include:

• Spreadsheet and tutorial for sorting products into families
• Spreadsheets for calculating equipment required and for determining the interval for Every Part Every Interval (EPEI)
• Samples of visual method sheets for standard work
• Case study value stream maps and mapping icons

Creating Mixed Model Value Streams Practical Lean Techniques for Building to Demand 2nd Table of contents:

Acknowledgments

Part I: Introduction

Questions for Mixed Model

Getting Started

Challenges of the Real Factory

A New Look at These Challenges with Value Stream Mapping

Where Do We Start?

Welcome to EMC Supply Company

Our Visit to EMC Supply

Mixed Model Production

Part II: Product Famailies and the Pacemaker

Question 1— Do We Have the Right Product Families?

Product Families: A Closer Look

Developing the Product Family Matrix at EMC

Refining the Product Families

The Current-State Map

Developing a Future State

Question 2— What Is the Takt Time at the Pacemaker?

Takt Time

Question 3— Can the Equipment Support the Takt Time?

Cycle Time

Question 4— What Is the Interval?

Determining the Interval

Part III: Flow at the Pacemaker

Question 5— What Are the Operator Balance Charts for the Products?

What Time Do We Balance To?

Creating Operator Balance Charts

Balancing Machine Cycles

Identifying the True Pacemaker

Material Presentation

Question 6—How Will We Balance Flow for the Mix?

Balancing Products with High Work Content into the Family

Varying Labor: A Closer Look

Changeovers At The Pacemaker

Question 7— How Will We Create Standard Work for the Mix?

Documenting Standard Work

Visual Method Sheets

Smart Tools And Standard Work

Part IV: Pitch and Scheduling

Question 8— How Will We Create the Pitch at the Pacemaker?

Leveling Using Pitch

The Schedule Box

Creating Pitch at EMC Supply

Inverse Pitch

The Future State

Question 9— How Will We Schedule the Mix at the Pacemaker?

Mix Logic Charts

Creating the Mix Logic Chart at EMC Supply

Leveling The Mix

Loading The Schedule Box

The Future State

Part V: Customer Demand

Question 10—How Will We Deal with Changes in Customer Demand?

Smoothing Demand with Dynamic Supermarkets

Building to Changing Customer Demand

Determining The Starting Point

The Future State

Part VI: How Will Upstream Processes Support the Pacemaker?

Offset Sequencing

Sequenced FIFO

Part VII: Putting It All Together

How Does It All Work?

Running The Future State

What’s Next For The Team?

Kevin J. Duggan on Lean

Appendices

Appendix A: Lean Glossary

Appendix B: EMC Supply Data Set

Important Sources

Index

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Tags: Kevin Duggan, Creating Mixed, Value Streams, Lean Techniques