Vandal boat factory simulation
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Vandal Boat Factory Simulation. Outline. Review of lean concepts Review the current state of Vandal paper factory VSM The products and practice Simulation 1 Role assignment Execution and data gathering Analysis Simulation 2

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Vandal Boat Factory Simulation

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Vandal boat factory simulation

Vandal Boat Factory Simulation


Outline

Outline

  • Review of lean concepts

  • Review the current state of Vandal paper factory

    • VSM

    • The products and practice

  • Simulation 1

    • Role assignment

    • Execution and data gathering

    • Analysis

  • Simulation 2

    • Review slides from day 4, transition to future state, calculating Takt time

    • Redesign

    • Execution and data gathering

    • Analysis

  • Simulation 3

    • Review slides from day 4, pacemaker process,

    • Redesign

    • Execution and data gathering

    • Analysis

  • Wrap up


Review

REVIEW


House of lean thinking

Best Quality, Cost, Delivery, Safety Defects and Morale (QCSDM)

House of Lean Thinking

PEOPLE & TEAMWORK

  • Just In Time

  • Operate with the minimum resource requirements to consistently produce

  • Just what is needed

  • Just the required amount

  • Just where it is needed

  • Just when it is needed

  • Jidoka

  • Built in Quality

  • In station quality: never pass a bad part onto the next process.

  • Poke Yoke (error proofing)

  • Automatic line stops (andon)

  • Man-Machine Separation

  • Prevent Problems (controls)

  • Root cause analysis (5 why’s)

  • Decision making

  • Common goals

  • Cross-training

  • Selection

CONTINUOUS IMPROVEMENT (KAIZEN)

  • Problem Solving

  • Eyes for Waste

  • GenchiGenbutsu: go to gemba

WASTE REDUCTION

Level Loaded Production

5S / Visual Management

Continuous Cost Reduction Through The Elimination of Waste


Forms of waste

Forms of Waste

5%

Value-Added

  • Defects

  • Overproduction

  • Waiting

  • Non-Value Added Processing.

  • Transportation

  • Inventory (Time)

  • Motion

  • Employees - Knowledge, Skills and Abilities

  • Energy and Environment

95%

Waste


Vandal paper boat factory

VANDAL PAPER BOAT FACTORY


Vandal boat factory simulation

SIMULATION

  • Round 1 (Traditional)

  • Round 2 (Student Redesigned)

  • Round 3 (Instructor Prompted)


Vandal boat factory simulation

Orientation

to the

Paper Boat Factory


Vandal boat factory simulation

Paper Boat Factory


Vandal boat factory simulation

Paper Boat Factory

GBWS


Vandal boat factory simulation

Paper Boat Factory

WBGS


Vandal boat factory simulation

$2.00/person/shift

$1.00/sqft/shift

$.25/sheet paper

Labor cost:

Facilities cost:

Material cost:

Paper Boat Factory:

GBWS

Sells for $8

Materials cost $0.50

WBGS

Sells for $8

Materials cost $0.50


Vandal boat factory simulation

PBF

  • Sales Representative Processes “Customer Order”

  • Production Scheduler Generates “Factory Order” from forecast

  • Kitter(s)Organizes raw materials for “Factory Orders”

  • Material HandlerMoves product between ALL workstations

  • Folder IInitial folding: Green

  • Folder I Initial folding: White

  • Folder IIFinal folding : Green

  • Folder IIFinal folding: White

  • Logo Stamper (white)

  • Logo Stamper (green)

  • Oven Operator (white)

  • Oven Operator (green)

Fabrication

  • Inspector(2)Assures Quality

  • ReworkerRepairs failed boats

  • Warehouse/Ship Clerk Matches boats to “Customer Orders”

  • Production Supervisor Supervises production

  • Industrial Engineer (2)Monitors production process

  • TruckerShips products to the customer


Vandal boat factory simulation

PBF

Green Paper

White Paper


Vandal boat factory simulation

PBF

GBWS

1 piece

1 piece

WBGS

1 piece

1 piece


Vandal boat factory simulation

PBF

GBWS

4 per batch

4 per batch

WBGS


Vandal boat factory simulation

PBF

Production Scheduling Process

Shipments

to

customers

Customer

orders

(demand)

Customer

order

forms

Production

forecast

Factory

order

forms

Finished

Goods

Warehouse


Vandal boat factory simulation

PBF

Promisedshipments to customers

Promised

shipments

to

customers

4 minutes after order

4 minutes after order

All orders are filled “first-in, first-out” (FIFO)


Vandal boat factory simulation

Paper Boat Factory

  • All shifts are 10 minutes

  • Keep busy at all times

  • Yell if you need parts

  • Handle all parts first-in, first-out (FIFO)

  • Only the Material Handler can move parts

  • Stay at your workstation

  • The boss is always right!


Set up

Set-up

  • Role assignment

  • Paper boat folding practice

  • Wet the line

  • IE data collection strategies/objectives


Vandal boat factory simulation

Paper Boat Factory

Round 1


Debriefing questions

Debriefing Questions

  • What forms of DOWNTIME waste were experienced in the simulation?

  • What opportunities exist for waste elimination through 5s/visual control?

  • How were issues of load leveling experienced?

  • In what areas of the factory were product flow best? Most problematic? Why?

  • What issues in product quality were encountered? What was the root cause of these defects?

  • Which jobs were most stressful? In what ways? Why is it important to engage workers in these positions in lean improvements?


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