Creating Mixed Model Value Streams: Practical Lean Techniques for Building to Demand

Creating Mixed Model Value Streams is a hands-on primer for those seeking to implement lean in complex environments. When faced with complex or unique situations, companies often disregard lean principles and fall back on previous practices. In this book, Kevin Duggan describes the lean techniques that can be used when faced with difficult situations such as high product mix, scheduling problems, shared resources, and unstable customer demand. This book will give mangers the knowledge to guide their companies through these tough obstacles and to attain positive bottom line results! The author uses a step-by-step approach, illustrated through a case study based on actual experience, to go beyond the basics of value stream mapping and show how to create future states in the real manufacturing world of multiple products, varying cycle times, and changing demand. The book includes a CD-ROM featuring useful spreadsheets for sorting products into families and calculating equipment needs. Comprehensive and down-to-earth, Creating Mixed Model Value Streams provides the details and new techniques for implementing lean in the complex environment that manufacturers face on their own shop floors. The Accompanying CD-ROM includes: Spreadsheet and tutorial for sorting products into families Spreadsheets for calculating equipment required and for determining the interval for EPEI (Every Part Every Interval) Samples of visual method sheets for standard work Case study value stream maps and mapping icons

Table of Contents:
INTRODUCTION Getting Started Challenges of the Real Factory A New Look at Challenges with Value Stream Mapping Where Do We Start? Welcome to EMC Supply Company Our Visit to EMC Supply Mixed Model Production PRODUCT FAMILIES and THE PACEMAKER Question 1: Do We Have the Right Families? Product Families - A Closer Look Developing the Product Family Matrix at EMC Refining Product Families The Current State Map Developing a Future State Question 2: What is the Takt Time at Pacemaker? Takt Time Question 3: Can the Equipment Support the Takt Time? Cycle Time Question 4: What is the Interval? Determining the Interval 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 PITCH AND SCHEDULING Question 8: What is 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 CUSTOMER DEMAND Question 10: How Will We Deal with Changes in Customer Demand? Smoothing Demand with Dynamic Supermarkets Determining the Starting Point The Future State PUTTING IT ALL TOGETHER How Does it All Work? Running the Future State What's Next for the Team? Glossary Important Sources Index