IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #8

IE 419 Work Design:Productivity and Safety Dr. Andris Freivalds Class #8 IE 419

OPERATIONS ANALYSIS(9 approaches, Ch. 3) • Basis for Lean Manufacturing • Analyze - Use operations analysis to simplify the method; • Eliminate steps • Combine steps • Rearrange steps IE 419

OPERATIONS ANALYSIS • Questions (examine): • Why? (Purpose) • Where? (Place) • When? (Sequence) • Who? (Operator) • How? (Method) IE 419

1) Operation Purpose • Eliminate unnecessary operations • Improper planning • Previous operations not correct (rework!) • Careful tooling IE 419

2) Part Design (simplify!) • ↓ number of parts • ↓ number of operations, length of travel • Use better material • Accuracy in 'key' operations • Design for manufact-urability and assembly IE 419

3) Tolerances and Specifications • Random vs. total inspection • Fatigue, human error • Cost vs. tolerance - cost increases exponentially IE 419

4) Materials • Less expensive • Easier to process • Using more efficiently or economically • Salvage materials • Standardization • Best vendor IE 419

5) Manufacturing Process • Rearrange operations • Mechanize • Increase efficiency • Near net shape • Use of robots IE 419

6) Setup and Tools • Reduce setup time vs. production time • Utilize full capacity • More efficient tooling • Group technology IE 419

7) Material Handling • Decrease time picking up material • Mechanical equipment • Better use of existing equipment • Handle with greater care • Bar coding (RFID) 8) Plant Layout 9) Work Design IE 419

Lean Manufacturing(History) • Toyota Production System, 1960s • Toyota problems: • Unsold inventory • Quality problems • Joke “Toy auto” • Taiichi Ohno, president of Toyota • Shigeo Shingo, main IE • Hiroyoki Hirano, management company IE 419

Lean Manufacturing(Basics) • JIT – just in time production • Push = scheduling by starting materials • Pull = final product produced as needed • SMED – single minute exchange of die • Kaizen – continuous improvement • Poka-Yoke – error proofing, quality control • Keiretsu – best vendor • Takt (Ger) – rhythm, cycle time • Muda – waste (need to eliminate) IE 419

7 Mudas • Overproduction → JIT • Waiting → line balancing, SMED • Transportation – no added value • Inappropriate processing • Unnecessary inventory – storage, wait times • Excess motion → ergonomics • Defects – rework, scrap → quality control 6σ IE 419

5 S – Workplace Organization IE 419

IE 419 Work Design: Productivity and Safety Dr. Andris Freivalds Class #8