施耐德产线设计-LADM for ETO

1、Line Architecture Design Methodology (LADM) By GSC T Assembly 2 By Francois BECQUET & William BU Purpose and learning objectives Understand, apply lean principles and SPS rules to assembly process design. Learning Objective Provide common methodologies, language and tools to: Define Takt Time, capac

2、ity requirement Optimize the Product/Process manufacturability Design process architecture & flows Define the Material Providing & Handling in PMP projects and reengineering projects. Course Content Industrialization Assembly Process Engineer Industrialization Project Leader Methods Engineer Target

3、Audience 3 By Francois BECQUET & William BU Value addition is judged by the customer Identify The Value Stream and eliminate non value added activities Real customer demand pulls products and information through the system Involve people in process transformation and commit them to manage the perfor

4、mance. Improvement opportunities are identified and implemented endless Main Lean principles 4 By Francois BECQUET & William BU 3. Transport 1. Overproduction 2. Waiting 6. Defects, Rework 4. Over processing 5. Motion 7. Inventory Reduce Non value added activities - Waste 5 By Francois BECQUET & Wil

5、liam BU SPS: Schneider Production System The mission of Schneider Production System is to improve quality and reduce cost while getting customers exactly what they want when they want it. The SPS is defined by 40 principles organized into 3 domains: People commitment, Product/process engineering, Ma

6、nagement of industrial and logistic processes. Product/process engineering: each product/process combination must be : Simple (Lean Manufacturing) Reliable (Design For Six Sigma) Flexible (almost zero change over time) Elastic (very quick changes in capacity) 6 By Francois BECQUET & William BU Trans

7、fer the responsibility to plant Prepare and transfer process “Industrial files” to the plants. Industrialization Assembly Contribution to PMP Concept and feasibility Definition Product & Process Design Implementation & Validation Production for stock Launch & closure Qualify the manufacturing equipm

8、ent and process Contribute to achieve the process performance objectives Define in details the manufacturing line architecture Establish the equipment and tools specifications Design the manufacturing process architecture Contribute to build the supply chain architecture Drive the product design to

9、optimize the manufacturability Provide and validate the assembly technology solutions Contribute to define the industrial objectives, constraints and risks Follow-up the realization of equipments and tools Manage the manufacturing prototypes and pilot Product 7 By Francois BECQUET & William BU LADM

10、Contribution to PMP Deliverables means that the deliverable are mandatory due to project efficiency, product quality and customer satisfaction 8 By Francois BECQUET & William BU LADM overview Process Design the assembly process, line architecture, flows, MPH and layout. Supply Chain Integrate the in

11、dustrial strategy and constraints of the overall supply chain architecture. Product Drive the product design to optimize the manufacturability and cost. Demand & Capacity Size the process capacity according to the customer demand. 9 By Francois BECQUET & William BU Historical data input SWOT analysi

12、s LADM detail steps Assembly Chronology Differentiation Tree Design for Assembly Elementary Operation Process Architecture Line Architecture Flows MPH & VSM Layout KPIs Supply Chain objective, organization and constraints Cmax: Max capacity needed Takt time reference List of parts by assembly sequen

13、ce Late differentiation optimization Assembly Manufacturability and max standardization Manufacturing Time UT,DT,OT KD optimization KER lost matrix nb. of operations, operators Process Balancing Flows of Production, Material, Operator and Information Material providing & handling with ABC/FMR Layout

14、 of workstation, line and plant Production Lead time Efficiency Quality FA ( File dattente) : to define the Cmax by simulating the order queue with historical demand and forecast U line Simulator: to verify the manufacturing process output and efficiency by simulating the production and MPH flow Pro

15、duct variants ABC Star reference or typical variant Historical Study Supply Chain Assumption Cmax & Takt time ref. Product Variant Analysis 10 By Francois BECQUET & William BU Historical Study Purpose: Refer to similar existing product/process or previous project experience to collect historical dat

16、a and identify risks & opportunities. Data Input: Existing product design Process flow & layout Manufacturing time Efficiency lost matrix & root cause analysis Quality historical report Manufacturing plant feedback Output Content: Manufacturability / testability report Reuse possibility in term of S

17、/A or process Existing technology solutions evaluation Manufacturing time database Efficiency & quality improvement opportunities Flow improvement analysis Safety and ergonomic analysis Tools/Tips: SWOT (Strength, Weakness, Opportunities, Threats) VSM (Value Stream Mapping) DFA Historical Study: Ref

18、erence from existing product/process Cmax & Takt Time ref Assembly Chronology Design for Assembly Elementary Operation Process Architecture Line Architecture Flows Layout KPI Supply Chain Assumption Differentiation Tree MPH & VSM Product Variant 11 By Francois BECQUET & William BU Historical Study:

19、Reference from existing product/process SWOT: use SWOT approach to analysis the strategy of new line. STRENGTHWEAKNESS THREATS Historical Study Cmax & Takt Time ref Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Supply Chain Assumption Differentiation Tr

20、ee Product Variant Line Architecture Flows MPH & VSM 12 By Francois BECQUET & William BU Purpose: Get assumptions from overall supply chain architecture, to take into account the industrial objectives, organization and constrains. Data Input: Plant locations ( FG and sub assemblies) Make or buy choi

21、ces ( parts and sub assemblies ) customer locations and delivery modes Output Content: Production organization of the plants Parts and sub assemblies mapping Production lead times Service levels Packaging / dispatching requirement Tools/Tips: EVSM (extended value stream mapping) Supply Chain Assumpt

22、ions: Industrial objectives and constrains Supply Chain Assumptions Historical Study Cmax & Takt Time ref Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Product Variant Line Architecture Flows MPH & VSM 13 By Francois BECQUET & Willi

23、am BU Supply Chain Assumptions: Industrial objectives and constrains Over all Supply Chain Plant workshop Production Lines Workstation / equipments As one part of supply chain, assembly process must be designed based on the overall supply chain organizations, and follow industrial objectives&constra

24、ints. Where and what to produce ? Whats lead time and service level target ? Whats the production organization ? Supply Chain Assumptions Historical Study Cmax & Takt Time ref Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Product Va

25、riant Line Architecture Flows MPH & VSM 14 By Francois BECQUET & William BU Purpose: According to customer demand, define the Cmax and Takt Time reference. Data Input: Forecast quantities by marketing Historical daily order quantities Service level objective Production lead time Plant production org

26、anization Output Content: Cmax Takt time reference Tools/Tips: 2 approach to calculate the Cmax: File dattente (Queue management simulation tool): a simulation tool to calculate the Cmax based on historical demand and forecast. SPS rules: 20% over peak forecast monthly demand ( if there is no availa

27、ble data to do FA analysis) Cmax & Takt Time reference: Capacity sizing based on max customer demand Cmax & TT ref Historical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Product Variant Supply Chain Assumption Line Architect

28、ure Flows MPH & VSM 15 By Francois BECQUET & William BU Cmax & Takt Time reference: Capacity sizing based on max customer demand Cmax (Max customer demand): Production capacity needed to meet the maximum customer demand. For capacity sizing, we need to take into account : Seasonality (demand variabi

29、lity) Service level 96.5% for MTS 100% for MTO / ETO Production lead time (delivery schedule) Manufacturing efficiency “FA” is the recommended tool to calculate the Cmax. Cmax = ? Cmax & TT ref Historical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout

30、KPI Differentiation Tree Product Variant Supply Chain Assumption Line Architecture Flows MPH & VSM 16 By Francois BECQUET & William BU DateQuantityDateQuantityDateQuantityDateQuantityDateQuantity 02/01/03 926705/03/03 4690228/04/03 15246524/06/03 5245515/08/03 115076 03/01/03 8604606/03/03 6465129/0

31、4/03 14681525/06/03 7034718/08/03 85079 06/01/03 5012707/03/03 3337330/04/03 11966426/06/03 19642819/08/03 89055 07/01/03 8370710/03/03 5664706/05/03 18502627/06/03 19121720/08/03 120069 08/01/03 7442411/03/03 7818907/05/03 4753230/06/03 18228421/08/03 121968 09/01/03 4709812/03/03 18215708/05/03 96

32、13901/07/03 12619122/08/03 74319 10/01/03 4569313/03/03 7498609/05/03 7304002/07/03 8605725/08/03 43971 13/01/03 6922714/03/03 8498612/05/03 7123003/07/03 4801426/08/03 134916 14/01/03 4246417/03/03 3038313/05/03 13523904/07/03 5658727/08/03 147150 15/01/03 4071818/03/03 7963014/05/03 6944107/07/03

33、5415228/08/03 154727 16/01/03 3735119/03/03 13733315/05/03 11972008/07/03 6394929/08/03 117341 17/01/03 3677120/03/03 7125116/05/03 16455309/07/03 5111801/09/03 106662 20/01/03 1866021/03/03 9306819/05/03 5314610/07/03 9105702/09/03 64269 21/01/03 2214124/03/03 5684020/05/03 5800011/07/03 11633003/0

34、9/03 43957 22/01/03 1322025/03/03 4555321/05/03 4180814/07/03 12303704/09/03 87706 23/01/03 4195926/03/03 9859622/05/03 7443115/07/03 8786405/09/03 128150 24/01/03 785427/03/03 10429023/05/03 4092816/07/03 5035408/09/03 39584 27/01/03 2507828/03/03 23047326/05/03 11873217/07/03 8884409/09/03 68273 2

35、8/01/03 3050431/03/03 4747727/05/03 5298818/07/03 15013610/09/03 67951 30/01/03 8915101/04/03 4541728/05/03 8627421/07/03 4845911/09/03 140852 09/02/03 4103402/04/03 15105229/05/03 12227222/07/03 10396312/09/03 95291 10/02/03 4534303/04/03 3736030/05/03 22509523/07/03 9892815/09/03 154789 11/02/03 1

36、765104/04/03 7783202/06/03 15003624/07/03 2817816/09/03 89856 12/02/03 5498207/04/03 3748903/06/03 7489825/07/03 7470017/09/03 34399 13/02/03 4635208/04/03 5195504/06/03 8853428/07/03 6690818/09/03 136273 14/02/03 2884209/04/03 3877805/06/03 2637329/07/03 13104522/09/03 164914 17/02/03 4405710/04/03

37、 2553606/06/03 6976630/07/03 20752923/09/03 38310 18/02/03 5594911/04/03 4596109/06/03 2164131/07/03 12051524/09/03 73404 19/02/03 4031914/04/03 22294210/06/03 4980501/08/03 10847325/09/03 154112 20/02/03 2335815/04/03 6761211/06/03 8695604/08/03 4428726/09/03 196345 21/02/03 7027316/04/03 11705012/

38、06/03 17117205/08/03 6148427/09/03 209995 24/02/03 3278817/04/03 5737413/06/03 3710606/08/03 9083228/09/03 80219 25/02/03 4314218/04/03 9136416/06/03 10629207/08/03 9713629/09/03 82437 26/02/03 12163321/04/03 12190417/06/03 12112608/08/03 4688330/09/03 80387 27/02/03 7191422/04/03 6000218/06/03 1398

39、1011/08/03 11805008/10/03 56115 28/02/03 10085223/04/03 14266819/06/03 15456712/08/03 8971809/10/03 60669 03/03/03 9085524/04/03 6463220/06/03 3605313/08/03 13577013/10/03 315472 04/03/03 3840825/04/03 4857823/06/03 5637814/08/03 11358214/10/03 96411 Cmax & Takt Time: File dattente ( Queue Managemen

40、t ) + Sample of FA data input: Historical daily demand - Refer to the existing / similar offer - i.e. one year of historical data Production time available - SPS rules: 2 shift for manual / 3 shift for auto - working hours from target factory organization Delivery objectives 1 2 3 Cmax & TT ref Hist

41、orical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Product Variant Supply Chain Assumption Line Architecture Flows MPH & VSM 17 By Francois BECQUET & William BU Cmax & Takt Time: File dattente ( Queue Management ) Sample of

42、FA output (daily simulation result): Service rate achieved Cmax (pcs/day) Order Queue Cmax & TT ref Historical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Product Variant Supply Chain Assumption Line Architecture Flows MPH &

43、 VSM 18 By Francois BECQUET & William BU Cmax & Takt Time: Takt Time reference An efficient process is a Just-in-Time process. Takt Time is one of the Lean Manufacturing fundamentals Make and Deliver n just what is needed n just when it is needed n just in the amount needed Takt Time reference = TT

44、ref: is the interval of time between the output of two products, to meet max customer demand. Production Time Available Cmax=max customer demand TT ref = * If there is no variation of customer demand, TT ref = TT * Product Variant Historical Study Assembly Chronology Design for Assembly Elementary O

45、peration Process Architecture Layout KPI Differentiation Tree Supply Chain Assumption Cmax & Takt Time ref Line Architecture Flows MPH & VSM 19 By Francois BECQUET & William BU Purpose: According to product mix volume and function analysis, to define the product variant which is used for following p

46、rocess design. Data Input: Volume by product mix Product functions analysis Output Content: Star Reference Or Typical Variant Tools/Tips: If its difficult to find a star reference, we create a typical variant which not exist but its representative of the process requirements. Product Variant: Find t

47、he star reference or typical variant Product Variant Historical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Supply Chain Assumption Cmax & Takt Time ref Line Architecture Flows MPH & VSM 20 By Francois BECQUET & William BU P

48、roduct Variant: Star reference definition Star Reference: a product reference which is the high runner of volume in product mix. Star Reference * Star Reference concept is used in product cost calculation also. Product Variant Historical Study Assembly Chronology Design for Assembly Elementary Opera

49、tion Process Architecture Layout KPI Differentiation Tree Supply Chain Assumption Cmax & Takt Time ref Line Architecture Flows MPH & VSM 21 By Francois BECQUET & William BU Product Variant: Typical variant definition Typical Variant: a theoretical product variant composed of all major features weigh

50、ted by their demand rates. The major features, functions, options and/or assemblies that differentiate the variant in terms of process: 1 = features used in the variant / 0 = feature not used Product Variant & Volume % (e.g. FG for MTO, main FG types for CTO.) A typical variants features = sum of vo

51、lume % x each feature Product Variant Historical Study Assembly Chronology Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Supply Chain Assumption Cmax & Takt Time ref Line Architecture Flows MPH & VSM 22 By Francois BECQUET & William BU Purpose: Refer t

52、o the product architecture to build the assembly route, identify the sub assemblies and the technical operations. Data Input: Parts list Product design (e.g. 3D) Prototypes Output Content: Assembly Chronology with: - parts / sub assemblies list by asembly sequence - technical operations (e.g. faster

53、ning, welding, marking, controls) Tools/Tips: Assembly chronology can be built by disassembly analysis Choose the high runner product variant and/or the most complex variant Assembly Chronology: Assembly Sequence vs. product architecture Assembly Chronology Historical Study Design for Assembly Eleme

54、ntary Operation Process Architecture Layout KPI Differentiation Tree Supply Chain Assumption Cmax & Takt Time ref Product Variant Line Architecture Flows MPH & VSM 23 By Francois BECQUET & William BU Assembly Chronology: Assembly Sequence vs. product architecture Assembly Sequ Assembly Sequence Part

55、s Name Material Input Symbol Sample of Assembly Chronology: Single partSub Assembly Assembly link Transform Operation (marking, welding, screwing, control) Assembly Chronology Historical Study Design for Assembly Elementary Operation Process Architecture Layout KPI Differentiation Tree Supply Chain

56、Assumption Cmax & Takt Time ref Product Variant Line Architecture Flows MPH & VSM 24 By Francois BECQUET & William BU Purpose: Promote late product differentiation and maximum component standardization Data Input: Assembly Chronology BOM by product reference Output Content: Differentiation tree Diff

57、erentiation chart Tools/Tips: Differentiation tree tool Differentiation Tree: Product & Parts Variants Differentiation Study Historical Study Design for Assembly Elementary Operation Process Architecture Layout KPI Supply Chain Assumption Cmax & Takt Time ref Product Variant Differentiation Tree Ass

58、embly Chronology Line Architecture Flows MPH & VSM 25 By Francois BECQUET & William BU Differentiation Tree: Product & Parts Variants Differentiation Study Reduce complexity reduce cost : minimize stock and WIP minimize investment ( machine & tool ) minimize Change over simplify the MPH simplify pro

59、duction management (simple flow) Late differentiation is part of “Design For Assembly”, it should be always promoted to product designer. variants Delay the point of differentiation as much as possible Upstream operations are standardized: Common components Common production lines Historical Study D

60、esign for Assembly Elementary Operation Process Architecture Layout KPI Supply Chain Assumption Cmax & Takt Time ref Product Variant Differentiation Tree Assembly Chronology Line Architecture Flows MPH & VSM 26 By Francois BECQUET & William BU Differentiation Tree: Product & Parts Variants Different