Following in the footsteps of its bestselling predecessor, Kevin J. Duggan, an executive mentor and recognized authority on Lean and Operational Excellence, draws on more than 10 years of experience and learning to provide Creating Mixed Model Value Streams, Second Edition. This second edition takes a step-by-step approach to implementing Lean in complex environments and describes which Lean techniques to use when faced with difficult situations-including high product mix, scheduling problems, shared resources, and unstable customer demand. In addition to a new section on handling shared resources to support mixed model production, the second edition: Contains updates to sections on mixed model value streams Introduces new information on constructing product family matrices Expands on the concept of takt in mixed models Provides additional insights on existing mixed model concepts, such as determining product family, takt capability, and heijunka (load level scheduling) Presents new concepts on sequencing work, such as offset scheduling and sequenced first-in, first-out (FIFO) lanes Illustrated with a case study based on actual experience as well as a CD with helpful tools, the book walks readers through the reasoning the author has used with great success in practice. It delves beyond the basics of value stream mapping to explain how to create future states in a manufacturing environment characterized by multiple products, varying cycle times, and changing demand. Demonstrating advanced techniques for creating flow through shared resources, it also considers the concept of a guaranteed turnaround time for the shared resource. The Accompanying CD Includes: Spreadsheet and tutorial for sorting products into families Spreadsheets for calculating equipment required and for determining the interval for Every Part Every Interval (EPEI) Samples of visual method sheets for standard work Case study value stream maps and mapping icons
Introduction Questions for Mixed Model Getting Started Challenges of the Real Factory A New Look at These 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 Product Families? Product Families: A Closer Look Developing the Product Family Matrix at EMC Refining the Product Families The Current-State Map Developing a Future State Question 2-What Is the Takt Time at the 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-How Will We Create 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 Building to Changing Customer Demand Determining the Starting Point The Future State How Will Upstream Processes Support the Pacemaker? Offset Sequencing Sequenced FIFO Putting It All Together How Does It All Work? Running the Future State What's Next for the Team? Kevin J. Duggan on Lean Appendices Lean Glossary EMC Supply Data Set Important Sources Index
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