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5_lean_manufactu - Lean Manufacturing Professor Deborah Nightingale Content General lean concepts in factory design Manufacturing Video

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Lean Manufacturing Professor Deborah Nightingale September 26, 2005
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Source: Tom Shields, Lean Aerospace Initiative Content General lean concepts in factory design Manufacturing Video Manufacturing System Design Framework Conclusions ESD.61J / 16.852J: Integrating the Lean Enterprise © Deborah Nightingale, 2005 Massachusetts Institute of Technology Page 2
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© Deborah Nightingale, 2005 Massachusetts Institute of Technology ESD.61J / 16.852J: Integrating the Lean Enterprise Page 3 Lean from the Toyota Production System Shows How It All Relates J I T J I D O K A Leveled & Balanced Production Cost control through the elimination of waste TPS Kaizen Standardized Work Right Qty Right Mix Right Time Perfect Quality Engaged and Creative Workforce
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Aerospace Factory Designs Have Many Things to Consider Inputs Production volume Product mix Product design Complexity Process capability Type of organization Factory Design Focus Frequency of changes Worker skill/knowledge Here Outputs Cost Quality Performance Delivery Flexibility Innovativeness ESD.61J / 16.852J: Integrating the Lean Enterprise © Deborah Nightingale, 2005 Massachusetts Institute of Technology Page 4
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Benefits from a Focus on Process Rather Than Operation Improvements Operations Value adding Transportation Delay (2 types) Inspection Factory Design Layout choices Operation policies Process Technology Tapping human knowledge X X Store in Warehouse Move to Staging Store at Staging Move By AGV Machine X X Part B Part A O p e r a t i o n Factory Design I X Storage Value Adding Inspection Transport Types of Operations ESD.61J / 16.852J: Integrating the Lean Enterprise © Deborah Nightingale, 2005 Massachusetts Institute of Technology Page 5
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Traditional Manufacturing l Assembly Center i Treat ly ion and Machining Center M M M M G G G G G G L L L L L L D D D D D MC MC D 1 4 2 3 5 10 7 6 8 9 12 13 11 Fina Receiving, Incoming Inspect on, and Shipping Heat Injection Molding Center Component Subassemb Inspect Test Center The material flow could take up to millions of different paths, creating waste of transportation and waiting at virtually every step. ESD.61J / 16.852J: Integrating the Lean Enterprise © Deborah Nightingale, 2005 Massachusetts Institute of Technology Page 6
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i ing Treat M G G L D M M G G L D D D MC MC M M G G L D D D Work Flow Receiving, Incoming Inspect on, and Shipp Heat Injection Molding Center Rather than route the materials required through the entire plant, materials flow to the head of each work cell, through each process in the cell, then to final assembly. This eliminates most of the transportation and waiting we would see in the traditional approach. ESD.61J / 16.852J: Integrating the Lean Enterprise © Deborah Nightingale, 2005 Massachusetts Institute of Technology Page 7
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This note was uploaded on 11/08/2011 for the course AERO 16.851 taught by Professor Ldavidmiller during the Fall '03 term at MIT.

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5_lean_manufactu - Lean Manufacturing Professor Deborah Nightingale Content General lean concepts in factory design Manufacturing Video

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