Lps01 lproduction

8/13/2018

LEAN PRODUCTION

GVC. ThS. Nguyễn Như Phong
; www.isem.edu.vn
Kỹ thuật Hệ thống Công nghiệp
ĐH BÁCH KHOA – ĐHQG TPHCM
(Tài liệu giảng dạy cho ISE)
2018

LEAN PRODUCTION

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Production System
Lean Production System

11 April 2003

Nguyễn Như Phong

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PRODUCTION SYSTEMS
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Production
Industries - Manufacturing industries
Types of production
Manufacturing functions
Info processing
Production organization
Flows in manufacturing
Effective manufacturing
PS Performance Measure
Nguyễn Như Phong

11 April 2003

PRODUCTION
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Production
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Transformation process
Convert RM into finished products

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Value in the marketplace

Product
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Intangible – service
Tangible – goods
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11 April 2003

Discrete
Continuous
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Difference bw. services & goods
Services

Goods

Output

intangible

Tangible

Kept in stock

No

Yes

Production &
consumption

simultaneous

Delay

Mass production

not

Possible

Server – customer
Interaction

A lot

Little / no

11 April 2003

Nguyễn Như Phong

Difference bw. services & goods

C participation
Facilities / factory 2 C
Resource
Q measurement
Q dependence
Output measurement

11 April 2003

Services

Goods

Yes
close
Labor intensive
Difficult
On the server
difficult

no

Far away
Largely automated
Easier
Not on one person
Usually

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Production
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Product made by a combination of
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Manual labor
Machinery
Tools
Energy

Transformation process

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Sequence of steps
Each step
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bring the material closer into the desired final state

The individual step – production operations
Nguyễn Như Phong

11 April 2003

INDUSTRIES
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Industries
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Service industries
Goods industries
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Manufacturing industries –
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Process industries –
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11 April 2003

discrete items
continuous items

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Manufacturing industries
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3 types form a transformation chain
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Basic producer
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Converter
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Natural resources  raw material
RM  uncomplicated items

Fabricator
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fabricate & assemble the final product
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11 April 2003

Produce component
Assemble components into consumer goods
Nguyễn Như Phong

TYPES OF PRODUCTION
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According 2 quantity of product made
Types of production
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Job shop production

Batch production
Mass production
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11 April 2003

Quantity production
Flow production

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Types of production
Job shop

Batch production

Mass production

Production quantity

Low volume, Small lot
size, often one of a kind

Medium-sized lot

Eg. 50

High volume

Variety

High

Medium

Low

Production rate

Low

Medium

High

Labor skill level

High

Med

Low

Equipment

Flexible & general
purpose

General purpose but
designed 4 high rate
production

Completely dedicated

Special tooling

Low

Med

High

Plant layout

Process

Process / Product

Product

Purpose

Meet specific cust. orders

Satisfy continuous

cust. demand

High demand rate of a
particular product

11 April 2003

Nguyễn Như Phong

MANUFACTURING FUNCTIONS
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Basic function to convert RM into FG
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Processing
Assembly
Material handling & storage
Inspection & test
Control

11 April 2003

Nguyễn Như Phong

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Processing operations
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Transform the product
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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

11 April 2003

Nguyễn Như Phong

Processing operations
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4 categories
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Basic processes
Secondary processes
Operations 2 enhance physical properties
Finishing operations

11 April 2003

Nguyễn Như Phong

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Processing operations
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Basic processes
 Give the work material initial form
 Eg.
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Metal casting,
plastic molding

Secondary processes
 Give the work part the final desired geometry
 Eg.
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Turning,
drilling, …

Nguyễn Như Phong

11 April 2003

Processing operations
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Operations to enhance physical properties
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Physical properties improved
Eg. Heat treating

Finishing operations

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Improve the appearance

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Eg.

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provide the protective coating on the work part
Painting,
polishing,
plating

Nguyễn Như Phong

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Processing operations
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Manufacturing process
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Inputs
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RM
Equipment
Tooling, fixture
Energy
Labor

Outputs
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Completed work piece
Scrap & waste
Nguyễn Như Phong

11 April 2003

Assembly

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Follow the processing operations
Assembly & joining processes
2 / more components joined together
Eg.
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Mechanical fastening
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screw, nut, rivets, …

Joining processes
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welding, brazing, soldering

11 April 2003

Nguyễn Như Phong

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Material handling & storage
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Moving & storing materials
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bw. processing & assembly operations

More time to move & store than to process
Majority of labor cost
As efficiently as pos.

Nguyễn Như Phong

11 April 2003

Inspection & test
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Part of QC
Inspection
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Whether the manufactured product meets
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the established standards &
specifications

Test concerned with
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functional specification of the final product

11 April 2003

Nguyễn Như Phong

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Control
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Process control
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Regulation
Achievement of performance objectives
 by proper manipulation of the inputs 2 the proc.

Nguyễn Như Phong

11 April 2003

Control
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Plant control
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Management
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Effective use of labor
Maintenance of equipment
Moving materials in the factory, …

Intersection bw.
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the physical operations
the info. processing activities

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INFO PROCESSING
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Info processing
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coordinating all of individual activities
required to
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make the parts
assemble parts
deliver the product 2 the cust.

11 April 2003

Nguyễn Như Phong

Info processing
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Info processing cycle
1.
2.
3.
4.

Business functions
Product design
Manu planning
Manu control

11 April 2003

Nguyễn Như Phong

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Business functions
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Business functions
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the principle mean of communicating w. the cust.
the beginning & the end of the IPC
include
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Sales & marketing
Sales forecasting
Order entry
Cost accounting
Customer billing, ...
Nguyễn Như Phong

11 April 2003

Business functions
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An order to produce a product
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typically originate
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from sales & marketing department

Production orders
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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

11 April 2003

Nguyễn Như Phong

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Product design
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New prod. design originate in SMD
Departments involved in PD
 R&D
 Design engineering,

 Drafting
 Prototype shop

Nguyễn Như Phong

11 April 2003

Product design
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PD
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Prototype built 4 testing & demonstration
ME department
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documented by component drawing, spec. & BOM.

consulted 2 lend advice on produce-ability

Whether-2-manu decision
1.
Engineering release –
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2.

approval by engineering management

Approval by corporate management.

11 April 2003

Nguyễn Như Phong

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Manu planning
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PD info & doc flow into MP function
Departments involved
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Manu. Engineering
IE
Production planning & control

11 April 2003

Nguyễn Như Phong

Manu planning
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MP
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Process planning
Master scheduling
Material requirement planning
Capacity planning

11 April 2003

Nguyễn Như Phong

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Manu planning
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Process planning
 Determine the sequence needed 2 produce the part
 Route sheet
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List of production operation & associated machine tools

ME & IE plan the processes & related manu. details

Nguyễn Như Phong

11 April 2003

Manu planning
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Master scheduling
 Authorization to produce
 Listing of prod to be made,
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11 April 2003

when,
what quantity

Nguyễn Như Phong

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Manu planning
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Material requirement planning
 RM requisitioned
 Purchased parts ordered available when needed
Capacity planning
 Manpower resources planning
 Machine resources planning

11 April 2003

Nguyễn Như Phong

Manu control
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Manage & control
 the physical operations in the factory
 to implement the MPs

Info flow
 from MP to MC
 back & forth bw. MC & factory operations

11 April 2003

Nguyễn Như Phong

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Manu control
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MC
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SFC
IC
QC

Nguyễn Như Phong

11 April 2003

SFC

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Monitoring the progress of product
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being processed, assembled, moved, inspected in
the SF
Production planning & control department
sessions involved in SFC
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11 April 2003

Scheduling
Dispatching
Expediting

Nguyễn Như Phong

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SFC
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Scheduling
 Assign start & due dates
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to the various parts & product made in the factory

 Parts produce 1by1 through machines listed in the RS
Dispatching
 Issuing the individual WOs
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to the m/c operators 2 accomplish the part processing

Performed by shop foreman / dispatcher

Nguyễn Như Phong

11 April 2003

SFC

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Expediting
 Things go wrong

 Expediter
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Compare the actual progress against the schedule

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Take the nec. corrective action 2 complete the order on time

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Orders fall-behind

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IC
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Strike a proper balance bw.
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the danger of too little inventory
the expense of having too much inventory

SFC - WIP

Nguyễn Như Phong

11 April 2003

QC
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Assure the products & components quality
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meet the standards specified by the PD

QC
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Inspection performed
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in the factory

from outside

Final inspection & testing of FG.

11 April 2003

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PS ORGANIZATION
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Marketing department
Sales department
Product engineering
Prototype department
Tooling department

Production engineering in the manu department
Purchasing department
Scheduling department in operation / manufacturing
Expediting
…

11 April 2003

Nguyeãn Nhö Phong

PS ORGANIZATION
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Marketing department
 Determine a need
Product engineering
 Design a prod 2 serve the need
Prototype department
 Build prototype 2 test the design

11 April 2003

Nguyễn Như Phong

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PS ORGANIZATION
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Tooling department
 Design tools 2 make a high-volume version
Production engineering in the manu department
 How 2 use tools 2 make prod.
Purchasing department
 Once design finalized
 Arrange 2 buy necessary materials

11 April 2003

Nguyễn Như Phong

PS ORGANIZATION
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Sales department

 Obtain order from retailers
Scheduling department in operation / manufacturing
 Make sure order internally consistent
 Shipment date set 4 sale & customer
Expediting
 Late delivery
 Customer  Sale  scheduling
 Move laggard orders forward

11 April 2003

Nguyễn Như Phong

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FLOWS IN MANUFACTURING
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3 kinds of flows
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Flow of materials
Flow of info
Flow of cost

Friday, April 11, 2003

Nguyễn Như Phong

Flows in manufacturing
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Flow of materials
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Technical production
conversion of RMs into products
Serial chain of functions
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Procurement,
production,
distribution,
inventory & sales

Friday, April 11, 2003

Nguyễn Như Phong

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Flows in manufacturing
Flow of info

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Planning & control of production
MPC – manu planning & control system
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Provide info to manage the FOM
Effectively utilize people & equipment
Coordinate internal with those of suppliers
Communicate w. C about market requirement

Friday, April 11, 2003

Nguyễn Như Phong

Flows in manufacturing
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Flow of cost
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value added in FOM
Cost accumulated w. successive activities

Friday, April 11, 2003

Nguyễn Như Phong

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Flows in manufacturing
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All benefits directly proportional to the flow speed
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Difficulties in controlling manufacturing decrease
Planning become more effective
Best use of resources
Eliminating problems interrupt / slow down FOM&I

Friday, April 11, 2003

Nguyễn Như Phong

EFFECTIVE MANUFACTURING PRINCIPLES
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Production problems
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Inventory
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more liability than an asset

Eliminating causes of downtime
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eliminated not covered up

better than inventory

More frequent & precise replanning

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not make it more accurate

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