Bài giảng Lean production systems - Chapter 1: Lean production - Nguyễn Như Phong
8/13/2018
LEAN PRODUCTION
GVC. ThS. Nguyễn Như Phong
Kỹ thuật Hệ thống Công nghiệp
ĐH BÁCH KHOA – ĐHQG TPHCM
(Tài liệu giảng dạy cho ISE)
2018
LEAN PRODUCTION
Production System
Lean Production System
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PRODUCTION SYSTEMS
Production
Industries - Manufacturing industries
Types of production
Manufacturing functions
Info processing
Production organization
Flows in manufacturing
Effective manufacturing
PS Performance Measure
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PRODUCTION
Production
Transformation process
Convert RM into finished products
Value in the marketplace
Product
Intangible – service
Tangible – goods
Discrete
Continuous
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Difference bw. services & goods
Services
Goods
intangible
No
Tangible
Yes
Output
Kept in stock
simultaneous
Delay
Production &
consumption
not
Possible
Mass production
A lot
Little / no
Server – customer
Interaction
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Difference bw. services & goods
Services
Goods
C participation
Facilities / factory 2 C
Resource
Yes
close
no
Far away
Labor intensive Largely automated
Q measurement
Q dependence
Output measurement
Difficult
On the server
difficult
Easier
Not on one person
Usually
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Production
Product made by a combination of
Manual labor
Machinery
Tools
Energy
Transformation process
Sequence of steps
Each step
bring the material closer into the desired final state
The individual step – production operations
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INDUSTRIES
Industries
Service industries
Goods industries
Manufacturing industries –
discrete items
Process industries –
continuous items
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Manufacturing industries
3 types form a transformation chain
Basic producer
Natural resources raw material
Converter
RM uncomplicated items
Fabricator
fabricate & assemble the final product
Produce component
Assemble components into consumer goods
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TYPES OF PRODUCTION
According 2 quantity of product made
Types of production
Job shop production
Batch production
Mass production
Quantity production
Flow production
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Types of production
Job shop
Batch production
Mass production
High volume
Production quantity
Low volume, Small lot
size, often one of a kind
Medium-sized lot
Eg. 50
Variety
High
Low
High
Medium
Medium
Med
Low
High
Low
Production rate
Labor skill level
Equipment
Flexible & general
purpose
General purpose but Completely dedicated
designed 4 high rate
production
Special tooling
Plant layout
Low
Med
High
Process
Process / Product
Product
Purpose
Meet specific cust. orders
Satisfy continuous
cust. demand
High demand rate of a
particular product
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MANUFACTURING FUNCTIONS
Basic function to convert RM into FG
Processing
Assembly
Material handling & storage
Inspection & test
Control
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Processing operations
Transform the product
from one state of completion
into a more advantage state of completion
No materials / components assembled / added
Energy added to
Change the shape
Remove material
Alter physical properties
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Processing operations
4 categories
Basic processes
Secondary processes
Operations 2 enhance physical properties
Finishing operations
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Processing operations
Basic processes
Give the work material initial form
Eg.
Metal casting,
plastic molding
Secondary processes
Give the work part the final desired geometry
Eg.
Turning,
drilling, …
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Processing operations
Operations to enhance physical properties
Physical properties improved
Eg. Heat treating
Finishing operations
Improve the appearance
provide the protective coating on the work part
Eg.
Painting,
polishing,
plating
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Processing operations
Manufacturing process
Inputs
RM
Equipment
Tooling, fixture
Energy
Labor
Outputs
Completed work piece
Scrap & waste
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Assembly
Follow the processing operations
Assembly & joining processes
2 / more components joined together
Eg.
Mechanical fastening
screw, nut, rivets, …
Joining processes
welding, brazing, soldering
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Material handling & storage
Moving & storing materials
bw. processing & assembly operations
More time to move & store than to process
Majority of labor cost
As efficiently as pos.
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Inspection & test
Part of QC
Inspection
Whether the manufactured product meets
the established standards &
specifications
Test concerned with
functional specification of the final product
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Control
Process control
Regulation
Achievement of performance objectives
by proper manipulation of the inputs 2 the proc.
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Control
Plant control
Management
Effective use of labor
Maintenance of equipment
Moving materials in the factory, …
Intersection bw.
the physical operations
the info. processing activities
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INFO PROCESSING
Info processing
coordinating all of individual activities
required to
make the parts
assemble parts
deliver the product 2 the cust.
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Info processing
Info processing cycle
1.
2.
3.
4.
Business functions
Product design
Manu planning
Manu control
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Business functions
Business functions
the principle mean of communicating w. the cust.
the beginning & the end of the IPC
include
Sales & marketing
Sales forecasting
Order entry
Cost accounting
Customer billing, ...
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Business functions
An order to produce a product
typically originate
from sales & marketing department
Production orders
Order to manufacture an item to a cust. spec.
Cust. order to buy 1 / more prod.s
Order based on a forecast of future demand
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Product design
New prod. design originate in SMD
Departments involved in PD
R&D
Design engineering,
Drafting
Prototype shop
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Product design
PD
documented by component drawing, spec. & BOM.
Prototype built 4 testing & demonstration
ME department
consulted 2 lend advice on produce-ability
Whether-2-manu decision
1. Engineering release –
approval by engineering management
2. Approval by corporate management.
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Manu planning
PD info & doc flow into MP function
Departments involved
Manu. Engineering
IE
Production planning & control
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Manu planning
MP
Process planning
Master scheduling
Material requirement planning
Capacity planning
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Manu planning
Process planning
Determine the sequence needed 2 produce the part
Route sheet
List of production operation & associated machine tools
ME & IE plan the processes & related manu. details
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Manu planning
Master scheduling
Authorization to produce
Listing of prod to be made,
when,
what quantity
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Manu planning
Material requirement planning
RM requisitioned
Purchased parts ordered available when needed
Capacity planning
Manpower resources planning
Machine resources planning
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Manu control
Manage & control
the physical operations in the factory
to implement the MPs
Info flow
from MP to MC
back & forth bw. MC & factory operations
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Manu control
MC
SFC
IC
QC
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SFC
Monitoring the progress of product
being processed, assembled, moved, inspected in
the SF
Production planning & control department
sessions involved in SFC
Scheduling
Dispatching
Expediting
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SFC
Scheduling
Assign start & due dates
to the various parts & product made in the factory
Parts produce 1by1 through machines listed in the RS
Dispatching
Issuing the individual WOs
to the m/c operators 2 accomplish the part processing
Performed by shop foreman / dispatcher
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SFC
Expediting
Things go wrong
Expediter
Compare the actual progress against the schedule
Orders fall-behind
Take the nec. corrective action 2 complete the order on time
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IC
Strike a proper balance bw.
the danger of too little inventory
the expense of having too much inventory
SFC - WIP
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QC
Assure the products & components quality
meet the standards specified by the PD
QC
Inspection performed
in the factory
from outside
Final inspection & testing of FG.
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