Alain Prioul Flexibility Adaptability 1 Definitions Flexibility Adaptability

Alain Prioul Flexibility / Adaptability 1

Definitions Flexibility Adaptability Ability to quickly change from one part number to another one Ability to follow customer demand at different Takt Time 2

Flexibility 3

Flexibility : Why ? To reduce WIP + surface + handling + CAPEX Key condition for high TRS Key condition for levelling To reduce lead time 4

Reduce inventories Q Stock level A Average stock t Safety stock Production (batch size 12 h) Q 12 h A B C A t 5

Reduce inventories Q Stock level A Safety stock Average stock t Production (batch size 2 h) 12 h Q A B C A B C t 6

Reduce inventories Q Stock level A Safety stock Average stock t Production (batch size 2 h) 12 h Q A B C A B C t 7

TRS Increase 100% 5 h 75% P 1 P 2 P 3 P 4 5 h 5 h B 9 h D F H A 9 h C E G P(x) 1 h 18 h 9

TRS Increase P 1 5 h 5 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 10

TRS Increase P 1 5 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 11

TRS Increase P 1 5 h 2 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 12

TRS Increase P 1 5 h 2 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 13

TRS Increase P 1 5 h 2 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 14

TRS Increase P 1 5 h 2 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 15

TRS Increase P 1 5 h 2 h 2 h 9 h 2 h 2 h 2 h 9 h x 2 P 3 P 4 P 5 P 6 2 h 2 h x 9 16

Flexibility : Why ? To reduce WIP + surface + handling + CAPEX Key condition for high TRS Key condition for levelling To reduce lead time 17

Levelling Ideal condition: Producing all products in parallel at TAKT TIME (rhythm of customer demand of each part number) Target : respect the TAKT TIME & full loading of the equipment: Producing all products in small batches close to TAKT TIME 18

Lead Time reduction Customer demand Production = Large batches Lead time Production = small batches Lead time 19

Adaptability : Flexible Manpower Line 20

Flexible Man Power Line : why ? Number of Operators = Work Content Takt Time Work Content change Result of Kaizen action Takt Time change Customer demand change Work content mix n => n - 1 21

Flexible Man Power Line : Definition Flexible Manpower Line A line which is designed in such a way that productivity is the same, whatever is the number of operators. Flexible Manpower System Optimizing labour productivity factory-wide by moving people from one flexible manpower line to another. 22

Flexible man power line : Layout Unflexible man power line U cell Linear (fixe) A B C D 23

Flexible Manpower Line : Fundamentals Line Operator Process • Linear line configuration or U shape line • No barrier to operator movement • Operators work inside the cell • Operator loaded to takt time • Operation start and finish at the same point • One piece product flow by hand • Standard in process stock Multi-process handling • Several Standard Work for varying demand • Flexible working hours 24

Flexible Manpower Line : Iso-productivity ! Demand 6 operators - 15 % => 5 operators PPH is constant Demand - 30 % => 4 operators Demand - 50 % => 3 operators 25

Flexible Manpower Line - avoid overproduction => less WIP , space , handling - smooth production => better usage of capacity - smooth material flow => control lead time - create standard conditions - make kaizen possible 26