Lean assembly: the nuts and bolts of making assembly operations flow
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York, NY
Productivity Press
2002
|
| Schlagworte: | |
| Online-Zugang: | Table of contents only Publisher description Inhaltsverzeichnis |
| Beschreibung: | Includes bibliographical references (p. 263-266) and index |
| Beschreibung: | XVII, 273 S. Ill., graph. Darst. 24 cm |
| ISBN: | 1563272636 |
Internformat
MARC
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| 100 | 1 | |a Baudin, Michel |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Lean assembly |b the nuts and bolts of making assembly operations flow |c by Michel Baudin |
| 264 | 1 | |a New York, NY |b Productivity Press |c 2002 | |
| 300 | |a XVII, 273 S. |b Ill., graph. Darst. |c 24 cm | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 500 | |a Includes bibliographical references (p. 263-266) and index | ||
| 650 | 7 | |a Administração da produção |2 larpcal | |
| 650 | 7 | |a Controle da produção |2 larpcal | |
| 650 | 7 | |a Just in time |2 larpcal | |
| 650 | 7 | |a Manufatura |2 larpcal | |
| 650 | 7 | |a Procédés de fabrication |2 ram | |
| 650 | 7 | |a Production - Contrôle |2 ram | |
| 650 | 7 | |a Production - Gestion |2 ram | |
| 650 | 4 | |a Production management | |
| 650 | 4 | |a Manufacturing processes | |
| 650 | 4 | |a Production control | |
| 650 | 4 | |a Just-in-time systems | |
| 650 | 0 | 7 | |a Montageplanung |0 (DE-588)4120760-9 |2 gnd |9 rswk-swf |
| 650 | 0 | 7 | |a Lean Production |0 (DE-588)4287302-2 |2 gnd |9 rswk-swf |
| 689 | 0 | 0 | |a Montageplanung |0 (DE-588)4120760-9 |D s |
| 689 | 0 | 1 | |a Lean Production |0 (DE-588)4287302-2 |D s |
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| 856 | 4 | 2 | |m HBZ Datenaustausch |q application/pdf |u http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016298992&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |3 Inhaltsverzeichnis |
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Datensatz im Suchindex
| _version_ | 1804137351857831936 |
|---|---|
| adam_text | Contents
Figures xi
Tables xvii
A guided tour 1
PAKT A. Analysis techniques 3
CHAPTER 1 Key issues of assembly operations 5
1.1. Whatisassembly? 6
Scope ofthis book , 6
Assembly = assembly andtest. 6
1.2. Factors in assembly Performance 8
Partsupply 8
Assembly work design 9
Examples 10
1.3. Waste in assembly work 11
¥s£cogii%ing waste in assembly work 11
Eliminating assembly waste 13
Leon Assembly V
CHAPTER 2 Product quantity analysis. 15
2.1. Purpose 16
2.2. The concept of P-Q analysis 17
Difference with Group Technology 18
2.3. Bill of mateaals analysis for mixed-flow lines 20
2.4. Order profiling for custom assembly 25
CHAPTER 3 Trend and seasonality analysis 27
3.1. Purpose 28
3.2. Responding to demand variability over time 29
3.3. Data aggregation 30
3.4. Makingthe sales datatalk 32
3.5. Demand variability upstream in the supply chain 37
3.6. Condusions 39
CHAPTER 4 Takt time and capacity 41
4.1. What is the takt time? 42
Definition ofthe term 42
Design takt time and Operation takt time. 44
4.2. Common mistakes about takt time 45
4.3. Why takt time matters 46
4.4. Global and local Performance 48
4.5. Takt time, labor requirements, and line design 50
The minimum requirednumberojassemblers 50
Assembler job design issms with short takt times 52
Assemblerjob design issues with lang takt times 55
PAKTE Assembly concepts 59
CHAPTER 5 Visuali^ingthe assemblyprocess. 61
5.1. Needs and evaluation criteria for visualization tools 62
5.2. The problem with facility blueprints 63
5.3. lists and assembly master tables 67
5.4. Abstract flow diagrams and their limitations 70
5.5. Layout diagrams with flows 75
Two-dimensional diagrams. 75
Three-dimensional drawings 78
vi Lean Assembly
Integration of text and drawings 79
5.6. Photographs 79
Import ofdigital photography. 79
Shopfloorphotographyguidelines 80
5.7. Video recordings 81
5.8. Cardboard mock-ups 81
5.9. Discrete-event simulations 82
CHAPTER 6 The concept of the assembly line 85
6.1. Whatis an assembly line? 86
6.2. Bench assembly versus the assembly line 87
Why assembly lines are still controversial. 88
Computing bench assembly with line assembly. 89
Exceptions: where the bench still wins 92
6.3. Assembly lines, assembly cells, and line segments 93
6.4. Assembly and subassembly 97
All assembly work done in one Single line 97
Final assembly line with subassembly feeder lines 98
Modular assembly 99
100
Pros and cons of subassembly Ifeeder lines 101
CHAPTER 7 Collecting assembly time data 103
7.1. Why this needs attention 103
7.2. Data collection methods 104
7.3. Current Status of time and motion studies in manufacturing 105
Predetermined time Standards in the automobile industry 105
MTMandMOST 107
7.4. Time studies with video recordings 111
CHAPTER 8 Line balanäng 113
8.1. Assembly line balancing 114
8.2. Rebalancing a dedicated line 115
8.3. Multiproduct lines with batch versus leveled sequencing 119
8.4. Balancing assembly time among products on a mixed-flow line 121
8.5. Deliberate imbalances 122
Leon Assembly VÜ
PART C Detailed design 125
CHAPTER 9 Assembly Station si^ing 127
9.1. Issues with assembly Station sizing 128
9.2. Assembly stations for small products 128
9.3. Assembly stations for large products 132
9.4. Ergonotnics and safety 136
Standing versus sitting 136
Work height and assembler height 139
9.5. Stations with required dwell times 140
CHAPTER 10 Detailed design of assembly stations 143
10.1. Issues with assembly Station details 144
10.2. Assembly fixtures 144
Fixtures formanualassembly 144
Fixtures for mechanized or automated assembly 149
In-line mechanicalautomation 151
10.3. Handheld tools 152
Tools attached to the Station and not to the assembler 152
Toolpositioning and orientation 154
10.4. Assembly instructions 157
Instruction sheets 157
Contents of instruction sheets for manual assembly 158
Content of instruction sheets for mechani^ed assembly 161
Instruction sheets for mixed-fhm assembly 162
Authoring instruction sheets 163
Use ofinformation technology. 163
10.5. Visible management 164
Selfexplanatory devices, markings, and color codes 164
Tower lights, stop ropes, and other types ofandons 166
Counters and production monitors 168
CHAPTER 11 Part presentation 171
11.1. Scope and purpose 172
Part presentation requirements 172
Controversies about pari presentation 175
11.2. Key principles of part presentation 176
Removal ofpackaging materials before deUvery 176
Location mithin arm s nach ofthe assembler 178
VW Lean Assembly
Orientation 179
-Adjustments to specificpari charaäeristics 181
Matchingquantities 182
Containers nrith dunnage for counting 184
Kitting versus line-side supply 185
11.3. Single-piece presentation and water Spiders 186
Singk-piece presentation 187
Water Spiders and supermarkets. 189
CHAPTER 12 Conveyance between stations 193
12.1. Issues with conveyance Systems 194
12.2. Goals forthe conveyance System 1%
12.3. A few types of conveyance Systems 197
Unpowered conveyance. 197
Poivered conveyance 199
CHAPTER 13 Assembly cells 201
13.1. About assembly cells 202
13.2. The motivation for cell conversion 203
13.3. Part supply to assembly cells 206
13.4. Range of applicability of the U-shape 208
13.5. Pseudo U-shaped cells 210
CHAPTER 14 Overall shape of assembly lines. 211
14.1. Beyond cells 211
14.2. Car and related assembly lines 212
14.3. Airplane assembly lines 218
PARTD Assembly quality 221
CHAPTER 15 Preventingpickingerrors 223
15.1. About this chapter 224
15.2. Mistake-proofing assembly operations 225
15.3. Approaches to automatic identification 226
15.4. Using kit pallets and product fixtures to prevent mistakes 228
15.5. Mistake-proofing lineside picking 231
15.6. Mistake-proofing the kitting process 235
15.7. From stores to theline 237
Lean Assembly ix
i
15.8. Storage and retrieval 238
15.9. Namingitems to avoid confusion 240
15.10. From the supplier to the dock 242
CHAPTER 16 Inspection, fest, andrework operations. 243
16.1. The issues of inspection, test, and rework 244
16.2. The literature 246
The quaüty controlliterature. 246
The lean manufacturing literature 246
The general literature on assembly 247
16.3. Is self-inspection possible? 247
16.4. Inspection and test sequencing 249
Sequencing by decreasingfigure ofmerit and its limitations 250
Sequencing by induction 252
16.5. Testing multiple units at once 254
16.6. Designing automatic binning operations 256
16.7. Rework operations 257
Sefinfictedrework 258
Rework operations 259
Bibliography 263
0.1. Books in English 264
0.2. Books in Japanese 265
0.3. Books in German 265
0.4. Books in French 266
Index 267
x Leon Assembly
Figures
FIGURE 1-1. Inspectionsat Toyota 8
FIGURE2-1. P-QAnalysis 17
FIGURE 2-2. Multi-tiered P-Q analysis 19
FIGURE 2-3. Number ofitems common topairs of products 24
FIGURE 2-4. Commonality ratios for a family of products 24
FIGURE 2-5. Order profiling S-curve 26
FIGURE 3-1. Responding to seasonal variations 30
FIGURE 3-2. Raw daily sales data for one product family over two
years 33
FIGURE 3-3. Trend and seasonality analysis 34
FIGURE 3-4. Finished goods inventory profile with steady
production 34
FIGURE 3-5. Production based on moving average of demand 36
FIGURE 3-6. Finished goods inventory profile with production based on
moving average of demand 37
FIGURE 4-1. The chairlift analogy for takt time in a mixed-flow line 44
FIGURE 4-2. Chevys 53-second takt time for tortillas 45
FIGURE 4-3. The ideal of takt-driven production 46
Lean Assembly XI
FIGURE 4-4. Approximation of takt-driven production 47
FIGURE4-5. The mixed-flowlineas äset of Virtual dedicatedünes 49
FIGURE 4-6. Possible breakdowns for a 100-minute assembly
process 51
FIGURE 4-7. Operators workingon batches ofparts 53
FIGURE 4-8. Replicated stations around a conveyor 54
FIGURE 4-9. Modules in a tanker hüll 56
FIGURE 4-10. Breaking long cycle into sequence of operations 57
FIGURE 4-11. Assembling very large products 58
FIGURE 5-1. Shop floor blueprint 63
FIGURE 5-2. Line design based on available Space 64
FIGURE 5-3. Spaghetti map of an assembly process 65
FIGURE 5-4. List of operations versus flow chart 67
FIGURE 5-5. An assembly master table 69
FIGURE 5-6. Flows of materials in a car assembly plant 70
FIGURE 5-7. An assembly cell layout drawing 76
FIGURE 5-8. Three-dimensional cartoon 78
FIGURE 5-9. Photomontage example of WIPremoval 79
FIGURE 5-10. Tips on shop floor photography 81
FIGURE 6-1. The assembly line 86
FIGURE 6-2. Ford Model T magneto assembly 87
FIGURE 6-3. High volume bench assembly versus the assembly line 90
FIGURE 6-4. A cell for cardiac monitor assembly in Japan 94
FIGURE 6-5. One long line or a sequence of cells? 95
FIGURE 6-6. A final assembly line segment at Toyota 96
FIGURE 6-7. Assembly in one single line 97
FIGURE 6-8. Subassembly feeder line 98
FIGURE 6-9. Dashboard assembly for cars 99
FIGURE 6-10. Modular assembly 99
FIGURE 6-11. Modular assembly for the Smart car in Hambach,
France 100
FIGURE 7-1. Physical load degree 110
FIGURE 8-1. The principle of assembly line balancing 116
Leon Assembly
FIGURE8-2. Steps to rebalancing a dedicated line 117
FIGURE 8-3. Parts for old and new version of Zebco 404 fishing
reel 122
FIGURE 8-4. Catching up in a deliberately imbalanced line 124
FIGURE 9-1. Large Station for small product 129
FIGURE 9-2. Critique of the 1913 Ford magneto assembly line 130
FIGURE 9-3. Phonograph assembly at Edison in the 1920s 131
FIGURE 9-4. Assembly of laser printer component at Canon
(1990 s) 132
FIGURE 9-5. Engine assembly at Toyota 133
FIGURE 9-6. The build saddle concept 134
FIGURE 9-7. Working underneath the product at NUMMI 134
FIGURE 9-8. Access to multiple sections in large product assembly 135
FIGURE 9-9. Sitting operations 136
FIGURE 9-10. Raku-raku seat at Toyota 138
FIGURE 9-11. Green corner example 139
FIGURE 9-12. Curing Station 141
FIGURE 9-13. Typesofovendoors 142
FIGURE 9-14. Oven Station example 142
FIGURE 10-1. An example of a pushcart fixture 145
FIGURE 10-2. Welding Station in non-rotating fixture 146
FIGURE 10-3. Lazy Susan for flexible Computer assembly 147
FIGURE 10-4. Fixture return to starting position in electronics
assembly 149
FIGURE 10-5. Orientationofaircylinders 150
FIGURE 10-6. Methods for starting assembly machines 151
FIGURE 10-7. In-line mechanical automation 152
FIGURE 10-8. Tools attached to stations versus assemblers 154
FIGURE 10-9. Tool placement 155
FIGURE 10-10. Spaceship moving tool fixture 156
FIGURE 10-11. Two approaches to assembler instructions 158
FIGURE 10-12. Instruction sheet concept 159
FIGURE 10-13. Assembly instructions for K nex Cybots 160
Leon Assembly XÜI
FIGURE 10-14. Work combination chart for mechanized assembly 162
FIGURE 10-15. Assigned locations and labeis 165
FIGURE 10-16. Red bin for defectives and ZD sticker 166
FIGURE 10-17. Effective use of tower lights 166
FIGURE 10-18. Good and bad designs for tower lights 167
FIGURE 10-19. Stop ropes and andon boards 168
FIGURE 10-20. Production monitors 169
FIGURE 11-1. The context of part presentation 172
FIGURE 11 -2. The assembler as race car driver 173
FIGURE 11-3. Net effect of adding a picker 174
FIGURE 11-4. The value added by preparing parts for use 176
FIGURE 11-5. Printed circuit boards with ESD protection 177
FIGURE 11-6. Separation of unpacking from assembly 178
FIGURE 11-7. Gravity flow racks 179
FIGURE 11-8. Techniques to keep parts within arm s reach 179
FIGURE 11-9. The orientation dilemma 180
FIGURE 11-10. Special presentation devices for large parts 181
FIGURE 11-11. Southworth s PaUetPal® 181
FIGURE 11-12. Random replenishment schedule 183
FIGURE 11-13. Divider boxes and item-specific dunnage 184
FIGURE 11-14. An example of a kit pallet 186
FIGURE 11-16. Single-piece presentation in electronics assembly 188
FIGURE 11-17. Part presentation in FRAPA versus single-piece
presentation 189
FIGURE 11-18. Example of water spider Operation 191
FIGURE 12-1. Spiral conveyor system 194
FIGURE 12-2. Example of part hanging on a chain (Westinghouse,
1904) 195
FIGURE 12-3. Partition blocking the view between two stations 196
FIGURE 12-4. Examples of unpowered conveyance Systems 198
FIGURE 12-5. Examples of powered conveyance Systems 199
FIGURE 13-1. A U-shaped assembly cell 204
FIGURE 13-4. Staffing flexibility in practice 206
XIV Lean Assembly
FIGURE 13-5. Three ways of supplying parts to an assembly cell 207
FIGURE 13-6. Vertical presentatdon for long parts 208
FIGURE 13-7. U-shaped cell for long and narrow product 209
FIGURE 13-8. A pseudo cell example 210
FIGURE 14-1. Volkswagen assembly line in 1953 212
FIGURE 14-2. Snaking assembly line 213
FIGURE 14-3. Reach of each materials service area 214
FIGURE 14-4. Layout of Toyota s Kyushu-Miyata plant 215
FIGURE 14-5. Snaking line with elevators between sections 216
FIGURE 14-6. Tow-cart shuttle 217
FIGURE 14-7. Boeing 717 assembly 218
FIGURE 14-8. B24 assembly line at Willow Run, Michigan during
WWII 220
FIGURE 15-1. Auto ID technologies used in manufacturing 227
FIGURE 15-2. Two approaches to detecting mismatch between kit and
assembly product 229
FIGURE 15-3. Assembly options tag or build manifest 230
FIGURE 15-4. Mistake-proofing using a flip-lid approach with a limit
switch 231
FIGURE 15-5. Mistake-prooding method based on a carrousel 232
FIGURE 15-6. Mistake-proofing using a flip-lid approach 233
FIGURE 15-7. Merry-go-round concept for small parts and multiple
products 234
FIGURE 15-8. A vertical carrousel System 235
FIGURE 15-9. Rack with pick-to-light boxes 236
FIGURE 15-10. Flow racks and push versus pull Systems 238
FIGURE 15-11. Approaches to warehouse visibility 240
FIGURE 15-12. Using fonts and styles to enhance distinctiveness 241
FIGURE 16-1. Sample pooling for blood testing 255
FIGURE 16-2. Testing multiple electronic assemblies 256
FIGURE 16-3. Automatic test equipment with binning capability 257
FIGURE 16-4. Offline rework Station 261
Leon Assembly XV
Tables
TABLE 1 -1. Use of assembler time in an aerospace assembly process 12
TABLE 1-2. Use of assembler time in an electronics assembly process 12
TABLE 2-1. List of procurement codes 24
TABLE 2-2. Items counts by category 24
TABLE 2-3. Part counts by product for a product family. 26
TABLE 2-4. Gozinto matrix sorted by decreasing consumption 27
TABLE 3-1. Weighted aggregate workload calculation 35
TABLE 3-2. Emergence of the buUwhip effect 43
TABLE 4-1. Typical takt times by industry 56
TABLE 5-1. A comparison of material flow mapping Symbols 78
TABLE 6-1. Bench vs. line with 100-min. process, takt time = 1 min. 97
TABLE 6-2. Bench vs. line with 100-min. process, takt time = 100 min. 98
TABLE 6-3. Pros and cons of subassembly 108
TABLE 8-1. Batch versus level sequencing in multiproduct lines 126
Lean Assembly XVÜ
|
| adam_txt |
Contents
Figures xi
Tables xvii
A guided tour 1
PAKT' A. Analysis techniques 3
CHAPTER 1 Key issues of assembly operations 5
1.1. Whatisassembly? 6
Scope ofthis book , 6
Assembly = assembly andtest. 6
1.2. Factors in assembly Performance 8
Partsupply 8
Assembly work design 9
Examples 10
1.3. Waste in assembly work 11
¥s£cogii%ing waste in assembly work 11
Eliminating assembly waste 13
Leon Assembly V
CHAPTER 2 Product quantity analysis. 15
2.1. Purpose 16
2.2. The concept of P-Q analysis 17
Difference with Group Technology 18
2.3. Bill of mateaals analysis for mixed-flow lines 20
2.4. Order profiling for custom assembly 25
CHAPTER 3 Trend and seasonality analysis 27
3.1. Purpose 28
3.2. Responding to demand variability over time 29
3.3. Data aggregation 30
3.4. Makingthe sales datatalk 32
3.5. Demand variability upstream in the supply chain 37
3.6. Condusions 39
CHAPTER 4 Takt time and capacity 41
4.1. What is the takt time? 42
Definition ofthe term 42
Design takt time and Operation takt time. 44
4.2. Common mistakes about takt time 45
4.3. Why takt time matters 46
4.4. Global and local Performance 48
4.5. Takt time, labor requirements, and line design 50
The minimum requirednumberojassemblers 50
Assembler job design issms with short takt times 52
Assemblerjob design issues with lang takt times 55
PAKTE Assembly concepts 59
CHAPTER 5 Visuali^ingthe assemblyprocess. 61
5.1. Needs and evaluation criteria for visualization tools 62
5.2. The problem with facility blueprints 63
5.3. lists and assembly master tables 67
5.4. Abstract flow diagrams and their limitations 70
5.5. Layout diagrams with flows 75
Two-dimensional diagrams. 75
Three-dimensional drawings 78
vi Lean Assembly
Integration of text and drawings 79
5.6. Photographs 79
Import ofdigital'photography. 79
Shopfloorphotographyguidelines 80
5.7. Video recordings 81
5.8. Cardboard mock-ups 81
5.9. Discrete-event simulations 82
CHAPTER 6 The concept of the assembly line 85
6.1. Whatis an assembly line? 86
6.2. Bench assembly versus the assembly line 87
Why assembly lines are still controversial. 88
Computing bench assembly with line assembly. 89
Exceptions: where the bench still wins 92
6.3. Assembly lines, assembly cells, and line segments 93
6.4. Assembly and subassembly 97
All assembly work done in one Single line 97
Final assembly line with subassembly feeder lines 98
Modular assembly 99
100
Pros and cons of subassembly Ifeeder lines 101
CHAPTER 7 Collecting assembly time data 103
7.1. Why this needs attention 103
7.2. Data collection methods 104
7.3. Current Status of time and motion studies in manufacturing 105
Predetermined time Standards in the automobile industry 105
MTMandMOST 107
7.4. Time studies with video recordings 111
CHAPTER 8 Line balanäng 113
8.1. Assembly line balancing 114
8.2. Rebalancing a dedicated line 115
8.3. Multiproduct lines with batch versus leveled sequencing 119
8.4. Balancing assembly time among products on a mixed-flow line 121
8.5. Deliberate imbalances 122
Leon Assembly VÜ
PART C Detailed design 125
CHAPTER 9 Assembly Station si^ing 127
9.1. Issues with assembly Station sizing 128
9.2. Assembly stations for small products 128
9.3. Assembly stations for large products 132
9.4. Ergonotnics and safety 136
Standing versus sitting 136
Work height and assembler height 139
9.5. Stations with required dwell times 140
CHAPTER 10 Detailed design of assembly stations 143
10.1. Issues with assembly Station details 144
10.2. Assembly fixtures 144
Fixtures formanualassembly 144
Fixtures for mechanized or automated assembly 149
In-line mechanicalautomation 151
10.3. Handheld tools 152
Tools attached to the Station and not to the assembler 152
Toolpositioning and orientation 154
10.4. Assembly instructions 157
Instruction sheets 157
Contents of instruction sheets for manual assembly 158
Content of instruction sheets for mechani^ed assembly 161
Instruction sheets for mixed-fhm assembly 162
Authoring instruction sheets 163
Use ofinformation technology. 163
10.5. Visible management 164
Selfexplanatory devices, markings, and color codes 164
Tower lights, stop ropes, and other types ofandons 166
Counters and production monitors 168
CHAPTER 11 Part presentation 171
11.1. Scope and purpose 172
Part presentation requirements 172
Controversies about pari presentation 175
11.2. Key principles of part presentation 176
Removal ofpackaging materials before deUvery 176
Location mithin arm's nach ofthe assembler 178
VW Lean Assembly
Orientation 179
-Adjustments to specificpari charaäeristics 181
Matchingquantities 182
Containers nrith dunnage for counting 184
Kitting versus line-side supply 185
11.3. Single-piece presentation and water Spiders 186
Singk-piece presentation 187
Water Spiders and supermarkets. 189
CHAPTER 12 Conveyance between stations 193
12.1. Issues with conveyance Systems 194
12.2. Goals forthe conveyance System 1%
12.3. A few types of conveyance Systems 197
Unpowered conveyance. 197
Poivered conveyance 199
CHAPTER 13 Assembly cells 201
13.1. About assembly cells 202
13.2. The motivation for cell conversion 203
13.3. Part supply to assembly cells 206
13.4. Range of applicability of the U-shape 208
13.5. Pseudo U-shaped cells 210
CHAPTER 14 Overall shape of assembly lines. 211
14.1. Beyond cells 211
14.2. Car and related assembly lines 212
14.3. Airplane assembly lines 218
PARTD Assembly quality 221
CHAPTER 15 Preventingpickingerrors 223
15.1. About this chapter 224
15.2. Mistake-proofing assembly operations 225
15.3. Approaches to automatic identification 226
15.4. Using kit pallets and product fixtures to prevent mistakes 228
15.5. Mistake-proofing lineside picking 231
15.6. Mistake-proofing the kitting process 235
15.7. From stores to theline 237
Lean Assembly ix
i
15.8. Storage and retrieval 238
15.9. Namingitems to avoid confusion 240
15.10. From the supplier to the dock 242
CHAPTER 16 Inspection, fest, andrework operations. 243
16.1. The issues of inspection, test, and rework 244
16.2. The literature 246
The quaüty controlliterature. 246
The lean manufacturing literature 246
The general literature on assembly 247
16.3. Is self-inspection possible? 247
16.4. Inspection and test sequencing 249
Sequencing by decreasingfigure ofmerit and its limitations 250
Sequencing by induction 252
16.5. Testing multiple units at once 254
16.6. Designing automatic binning operations 256
16.7. Rework operations 257
Sefinfictedrework 258
Rework operations 259
Bibliography 263
0.1. Books in English 264
0.2. Books in Japanese 265
0.3. Books in German 265
0.4. Books in French 266
Index 267
x Leon Assembly
Figures
FIGURE 1-1. Inspectionsat Toyota 8
FIGURE2-1. P-QAnalysis 17
FIGURE 2-2. Multi-tiered P-Q analysis 19
FIGURE 2-3. Number ofitems common topairs of products 24
FIGURE 2-4. Commonality ratios for a family of products 24
FIGURE 2-5. Order profiling S-curve 26
FIGURE 3-1. Responding to seasonal variations 30
FIGURE 3-2. Raw daily sales data for one product family over two
years 33
FIGURE 3-3. Trend and seasonality analysis 34
FIGURE 3-4. Finished goods inventory profile with steady
production 34
FIGURE 3-5. Production based on moving average of demand 36
FIGURE 3-6. Finished goods inventory profile with production based on
moving average of demand 37
FIGURE 4-1. The chairlift analogy for takt time in a mixed-flow line 44
FIGURE 4-2. Chevys 53-second takt time for tortillas 45
FIGURE 4-3. The ideal of takt-driven production 46
Lean Assembly XI
FIGURE 4-4. Approximation of takt-driven production 47
FIGURE4-5. The mixed-flowlineas äset of Virtual dedicatedünes 49
FIGURE 4-6. Possible breakdowns for a 100-minute assembly
process 51
FIGURE 4-7. Operators workingon batches ofparts 53
FIGURE 4-8. Replicated stations around a conveyor 54
FIGURE 4-9. Modules in a tanker hüll 56
FIGURE 4-10. Breaking long cycle into sequence of operations 57
FIGURE 4-11. Assembling very large products 58
FIGURE 5-1. Shop floor blueprint 63
FIGURE 5-2. Line design based on available Space 64
FIGURE 5-3. Spaghetti map of an assembly process 65
FIGURE 5-4. List of operations versus flow chart 67
FIGURE 5-5. An assembly master table 69
FIGURE 5-6. Flows of materials in a car assembly plant 70
FIGURE 5-7. An assembly cell layout drawing 76
FIGURE 5-8. Three-dimensional cartoon 78
FIGURE 5-9. Photomontage example of WIPremoval 79
FIGURE 5-10. Tips on shop floor photography 81
FIGURE 6-1. The assembly line 86
FIGURE 6-2. Ford Model T magneto assembly 87
FIGURE 6-3. High volume bench assembly versus the assembly line 90
FIGURE 6-4. A cell for cardiac monitor assembly in Japan 94
FIGURE 6-5. One long line or a sequence of cells? 95
FIGURE 6-6. A final assembly line segment at Toyota 96
FIGURE 6-7. Assembly in one single line 97
FIGURE 6-8. Subassembly feeder line 98
FIGURE 6-9. Dashboard assembly for cars 99
FIGURE 6-10. Modular assembly 99
FIGURE 6-11. Modular assembly for the Smart car in Hambach,
France 100
FIGURE 7-1. Physical load degree 110
FIGURE 8-1. The principle of assembly line balancing 116
Leon Assembly
FIGURE8-2. Steps to rebalancing a dedicated line 117
FIGURE 8-3. Parts for old and new version of Zebco 404 fishing
reel 122
FIGURE 8-4. Catching up in a deliberately imbalanced line 124
FIGURE 9-1. Large Station for small product 129
FIGURE 9-2. Critique of the 1913 Ford magneto assembly line 130
FIGURE 9-3. Phonograph assembly at Edison in the 1920s 131
FIGURE 9-4. Assembly of laser printer component at Canon
(1990's) 132
FIGURE 9-5. Engine assembly at Toyota 133
FIGURE 9-6. The build saddle concept 134
FIGURE 9-7. Working underneath the product at NUMMI 134
FIGURE 9-8. Access to multiple sections in large product assembly 135
FIGURE 9-9. Sitting operations 136
FIGURE 9-10. Raku-raku seat at Toyota 138
FIGURE 9-11. Green corner example 139
FIGURE 9-12. Curing Station 141
FIGURE 9-13. Typesofovendoors 142
FIGURE 9-14. Oven Station example 142
FIGURE 10-1. An example of a pushcart fixture 145
FIGURE 10-2. Welding Station in non-rotating fixture 146
FIGURE 10-3. Lazy Susan for flexible Computer assembly 147
FIGURE 10-4. Fixture return to starting position in electronics
assembly 149
FIGURE 10-5. Orientationofaircylinders 150
FIGURE 10-6. Methods for starting assembly machines 151
FIGURE 10-7. In-line mechanical automation 152
FIGURE 10-8. Tools attached to stations versus assemblers 154
FIGURE 10-9. Tool placement 155
FIGURE 10-10. "Spaceship" moving tool fixture 156
FIGURE 10-11. Two approaches to assembler instructions 158
FIGURE 10-12. Instruction sheet concept 159
FIGURE 10-13. Assembly instructions for K'nex Cybots 160
Leon Assembly XÜI
FIGURE 10-14. Work combination chart for mechanized assembly 162
FIGURE 10-15. Assigned locations and labeis 165
FIGURE 10-16. Red bin for defectives and ZD sticker 166
FIGURE 10-17. Effective use of tower lights 166
FIGURE 10-18. Good and bad designs for tower lights 167
FIGURE 10-19. Stop ropes and andon boards 168
FIGURE 10-20. Production monitors 169
FIGURE 11-1. The context of part presentation 172
FIGURE 11 -2. The assembler as race car driver 173
FIGURE 11-3. Net effect of adding a picker 174
FIGURE 11-4. The value added by preparing parts for use 176
FIGURE 11-5. Printed circuit boards with ESD protection 177
FIGURE 11-6. Separation of unpacking from assembly 178
FIGURE 11-7. Gravity flow racks 179
FIGURE 11-8. Techniques to keep parts within arm's reach 179
FIGURE 11-9. The orientation dilemma 180
FIGURE 11-10. Special presentation devices for large parts 181
FIGURE 11-11. Southworth's PaUetPal® 181
FIGURE 11-12. Random replenishment schedule 183
FIGURE 11-13. Divider boxes and item-specific dunnage\ 184
FIGURE 11-14. An example of a kit pallet 186
FIGURE 11-16. Single-piece presentation in electronics assembly 188
FIGURE 11-17. Part presentation in FRAPA versus single-piece
presentation 189
FIGURE 11-18. Example of water spider Operation 191
FIGURE 12-1. Spiral conveyor system 194
FIGURE 12-2. Example of part hanging on a chain (Westinghouse,
1904) 195
FIGURE 12-3. Partition blocking the view between two stations 196
FIGURE 12-4. Examples of unpowered conveyance Systems 198
FIGURE 12-5. Examples of powered conveyance Systems 199
FIGURE 13-1. A U-shaped assembly cell 204
FIGURE 13-4. Staffing flexibility in practice 206
XIV Lean Assembly
FIGURE 13-5. Three ways of supplying parts to an assembly cell 207
FIGURE 13-6. Vertical presentatdon for long parts 208
FIGURE 13-7. U-shaped cell for long and narrow product 209
FIGURE 13-8. A pseudo cell example 210
FIGURE 14-1. Volkswagen assembly line in 1953 212
FIGURE 14-2. Snaking assembly line 213
FIGURE 14-3. Reach of each materials service area 214
FIGURE 14-4. Layout of Toyota's Kyushu-Miyata plant 215
FIGURE 14-5. Snaking line with elevators between sections 216
FIGURE 14-6. Tow-cart shuttle 217
FIGURE 14-7. Boeing 717 assembly 218
FIGURE 14-8. B24 assembly line at Willow Run, Michigan during
WWII 220
FIGURE 15-1. Auto ID technologies used in manufacturing 227
FIGURE 15-2. Two approaches to detecting mismatch between kit and
assembly product 229
FIGURE 15-3. Assembly options tag or build manifest 230
FIGURE 15-4. Mistake-proofing using a flip-lid approach with a limit
switch 231
FIGURE 15-5. Mistake-prooding method based on a carrousel 232
FIGURE 15-6. Mistake-proofing using a flip-lid approach 233
FIGURE 15-7. Merry-go-round concept for small parts and multiple
products 234
FIGURE 15-8. A vertical carrousel System 235
FIGURE 15-9. Rack with pick-to-light boxes 236
FIGURE 15-10. Flow racks and push versus pull Systems 238
FIGURE 15-11. Approaches to warehouse visibility 240
FIGURE 15-12. Using fonts and styles to enhance distinctiveness 241
FIGURE 16-1. Sample pooling for blood testing 255
FIGURE 16-2. Testing multiple electronic assemblies 256
FIGURE 16-3. Automatic test equipment with binning capability 257
FIGURE 16-4. Offline rework Station 261
Leon Assembly XV
Tables
TABLE 1 -1. Use of assembler time in an aerospace assembly process 12
TABLE 1-2. Use of assembler time in an electronics assembly process 12
TABLE 2-1. List of procurement codes 24
TABLE 2-2. Items counts by category 24
TABLE 2-3. Part counts by product for a product family. 26
TABLE 2-4. Gozinto matrix sorted by decreasing consumption 27
TABLE 3-1. Weighted aggregate workload calculation 35
TABLE 3-2. Emergence of the buUwhip effect 43
TABLE 4-1. Typical takt times by industry 56
TABLE 5-1. A comparison of material flow mapping Symbols 78
TABLE 6-1. Bench vs. line with 100-min. process, takt time = 1 min. 97
TABLE 6-2. Bench vs. line with 100-min. process, takt time = 100 min. 98
TABLE 6-3. Pros and cons of subassembly 108
TABLE 8-1. Batch versus level sequencing in multiproduct lines 126
Lean Assembly XVÜ |
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| author | Baudin, Michel |
| author_facet | Baudin, Michel |
| author_role | aut |
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| bvnumber | BV023096196 |
| callnumber-first | T - Technology |
| callnumber-label | TS155 |
| callnumber-raw | TS155 .B34 2002 |
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| ctrlnum | (OCoLC)50270488 (DE-599)BVBBV023096196 |
| dewey-full | 658.5/1 |
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| dewey-ones | 658 - General management |
| dewey-raw | 658.5/1 |
| dewey-search | 658.5/1 |
| dewey-sort | 3658.5 11 |
| dewey-tens | 650 - Management and auxiliary services |
| discipline | Fertigungstechnik Arbeitswissenschaften Wirtschaftswissenschaften Maschinenbau |
| discipline_str_mv | Fertigungstechnik Arbeitswissenschaften Wirtschaftswissenschaften Maschinenbau |
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| id | DE-604.BV023096196 |
| illustrated | Illustrated |
| index_date | 2024-07-02T19:43:10Z |
| indexdate | 2024-07-09T21:10:55Z |
| institution | BVB |
| isbn | 1563272636 |
| language | English |
| lccn | 2002011613 |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-016298992 |
| oclc_num | 50270488 |
| open_access_boolean | |
| owner | DE-91 DE-BY-TUM |
| owner_facet | DE-91 DE-BY-TUM |
| physical | XVII, 273 S. Ill., graph. Darst. 24 cm |
| publishDate | 2002 |
| publishDateSearch | 2002 |
| publishDateSort | 2002 |
| publisher | Productivity Press |
| record_format | marc |
| spelling | Baudin, Michel Verfasser aut Lean assembly the nuts and bolts of making assembly operations flow by Michel Baudin New York, NY Productivity Press 2002 XVII, 273 S. Ill., graph. Darst. 24 cm txt rdacontent n rdamedia nc rdacarrier Includes bibliographical references (p. 263-266) and index Administração da produção larpcal Controle da produção larpcal Just in time larpcal Manufatura larpcal Procédés de fabrication ram Production - Contrôle ram Production - Gestion ram Production management Manufacturing processes Production control Just-in-time systems Montageplanung (DE-588)4120760-9 gnd rswk-swf Lean Production (DE-588)4287302-2 gnd rswk-swf Montageplanung (DE-588)4120760-9 s Lean Production (DE-588)4287302-2 s DE-604 text/html http://www.loc.gov/catdir/toc/fy0712/2002011613.html Table of contents only text/html http://www.loc.gov/catdir/enhancements/fy0801/2002011613-d.html Publisher description HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016298992&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Baudin, Michel Lean assembly the nuts and bolts of making assembly operations flow Administração da produção larpcal Controle da produção larpcal Just in time larpcal Manufatura larpcal Procédés de fabrication ram Production - Contrôle ram Production - Gestion ram Production management Manufacturing processes Production control Just-in-time systems Montageplanung (DE-588)4120760-9 gnd Lean Production (DE-588)4287302-2 gnd |
| subject_GND | (DE-588)4120760-9 (DE-588)4287302-2 |
| title | Lean assembly the nuts and bolts of making assembly operations flow |
| title_auth | Lean assembly the nuts and bolts of making assembly operations flow |
| title_exact_search | Lean assembly the nuts and bolts of making assembly operations flow |
| title_exact_search_txtP | Lean assembly the nuts and bolts of making assembly operations flow |
| title_full | Lean assembly the nuts and bolts of making assembly operations flow by Michel Baudin |
| title_fullStr | Lean assembly the nuts and bolts of making assembly operations flow by Michel Baudin |
| title_full_unstemmed | Lean assembly the nuts and bolts of making assembly operations flow by Michel Baudin |
| title_short | Lean assembly |
| title_sort | lean assembly the nuts and bolts of making assembly operations flow |
| title_sub | the nuts and bolts of making assembly operations flow |
| topic | Administração da produção larpcal Controle da produção larpcal Just in time larpcal Manufatura larpcal Procédés de fabrication ram Production - Contrôle ram Production - Gestion ram Production management Manufacturing processes Production control Just-in-time systems Montageplanung (DE-588)4120760-9 gnd Lean Production (DE-588)4287302-2 gnd |
| topic_facet | Administração da produção Controle da produção Just in time Manufatura Procédés de fabrication Production - Contrôle Production - Gestion Production management Manufacturing processes Production control Just-in-time systems Montageplanung Lean Production |
| url | http://www.loc.gov/catdir/toc/fy0712/2002011613.html http://www.loc.gov/catdir/enhancements/fy0801/2002011613-d.html http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=016298992&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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