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1、Industrial Engineering Line Design Procedure Expectations ExchangePlease tell us4Whats been the biggest challenge when designing or modifying a mechanical assembly line at your facility?4 From an Engineers point of view 4 From a Functional Managers point of view simple to execute with minimal opport
2、unity for error efficient enough to achieve the best value solution for our customer and our company flexible enough to meet our ever changing customer demands Jabil must be able to react quickly to a customer change in our customers demands and a dynamic business environment.As a result of this shi
3、ft,we hav adjusted our manufacturing processes to conform to our customers ever changing needs Objectives of the SessionA consistent understanding of the Industrial Engineerings approach to Line Design within Jabils production environmentA toolkit of strategies and methodologies for successfully exe
4、cuting line designs that are:4Simple to execute with minimal error4Flexible enough to meet Jabils ever changing customer demands4Efficient enough to achieve the best value solutions for Jabil and its customers By the end of this module,you will have:Philosophy/ApproachAs a group,brainstorm 4What do
5、we mean by“flexible,scalable,and modular”line design at Jabil?4Flexible line design?4Scalable line design?4Modular line design?able to re-deploy all of the equipment to existing customers able to add work content to a workstation without major reconfiguration able to react quickly and with ease to c
6、hanging market conditions able to develop processes simple enough that anyone can perform able to adapt to unexpected changes of order volume for existing products able to add capacity to the line in small increments able to reconfigure an existing workstation quickly and cost effectively able to ad
7、d stations without interrupting production able to source and utilize multifunctional equipment Philosophy/ApproachAs a group,brainstorm 4With regard to cost,what do we mean by“a flexible,scalable and modular line design in a cost effective manner”?4Cost Effective?for Jabil&the customers design what
8、 is needed,not just in case or excess design what customer need not what customer want simpler solution whenever possible cost justification to the affordability“bare bone”does not mean the most effective way search for used but good equipment thru ww network sometime greater investment might be req
9、uired upfront for different product life cycleBusiness Perspective4On the importance of“a simple system that is flexible,scalable and modular in a cost effective manner with minimum waste for Jabils dynamic business environment”-Ken PinkleyPhilosophy/ApproachAs a group,lets respond to the Business P
10、erspective 4What can you do to ensure that the engineers develop a simple system that is“flexible,scalable and modular in a cost effective manner with minimum waste for our customers and for Jabil”?standardize the approaches coach our customers on cost effective processes make use of the suppliers f
11、or newer and more cost effective technologies make the target/objective be visible to all engineers help others to practice lean manufacturing as well make others to understand wastes and value-add Line DesignA new customer has signed a contract with Jabil.The workcell manager is asking you to devel
12、op a plan that outlines all the information that you need to know and how your team will design a mechanical assembly back end for new product“X”.Assume that this is a Low Volume High Mix product.More specifically she is asking you to outline:4What information will you need in order to start the des
13、ign?(Document using a bulleted list format that describes the information youll need to assess and successfully design a line.)4What series of steps will you take to convert that information into meaningful data?(Looking for a list,step 1,step 2,etc.)4What kind of IE tools will you use to develop a
14、line design?(At each of the steps listed above,what IE tools would you recommend to use?)You have 20 minutes to Discuss and Document your ideas Summarize your outcomes to the entire Group,explaining any exceptions/differences Group Leaders-use mark up tools whenever possibleCase Study One-ApproachCa
15、se Study One:Approach-Line Design 4What information will you need in order to start the design?(Document using a bulleted list format that describes the information youll need to assess and successfully design a line.)4What series of steps will you take to convert that information into meaningful da
16、ta?(Looking for a list,step 1,step 2,etc.)4What kind of IE tools will you use to develop a line design?(At each of the steps listed above,what IE tools would you recommend to use?)Information Data Conversion Steps IE TOOLS BOM Test plan Machines/equipment spec TAKT/cycle time Product metrics Yields
17、Quality&workmanship std Sample/drawings Demand variation Cost targets Product design Space required Resources constraints Materials lot size Production schedule Customer expectation Delivery pattern etcCommon part breakdown Process flow chart Handling method Machines requirement MOST&time study Mate
18、rials flow Customer expectation Demand forecast&analysis RFQ Layout etc Process flow chart MOST Auto Cad Cap Model Value stream mapping VA NVA analysis Simulation RFQ Layout FMEA etcLine Design Process MappingWhat must we know first?4What is to be produced?-understand the product mix4How much will b
19、e produced?-show a forecast,upsides,history4How will the product be made?use and scrub the BOM and review the Process Flow if available4How will the raw material arrive?Qty/Size?(Per medium)4What is the expected life cycle of the product?(Sample timings,proto builds,production,end of life,customer p
20、roduction schedule)4At what location will the product be manufactured?4What kind of manufacturing floor space has been assigned for this project?Line Design Process MappingAs a group,lets discuss 4Why is it important to properly analyze and categorize all of the data weve described?4How would you in
21、struct your Engineers to interpret and organize this information?Do the right thing right,at the right time and right place,and at 1st time If you do not have the right info,the assumption might be based on inaccurate judgment or wrong data Theres no golden rule,a lot would be from experiences FM to
22、 guide the junior engineers ASK,do not assume Line Design Process MappingThe first step is to Chart the information 4P-Q(Product-Quantity)Analysis4Objective Determine if product mix requires independent manufacturingLine Design Process MappingNext 4P-R(Product-Routing)Analysis4Results visibility to
23、similar types of operations and similar types of products.Line Design Process MappingNext 4Q-R(Quantity-Routing)Analysis4Results visibility to material handlingLine Design Process MappingNext 4P-Q-T(Product-Quantity-Time)Analysis4Results balance between production staff and flexibility of the line4R
24、esults shows variation in volumes of product over timeProcess DiagnosisSet a vision for the design of the process 4Set baseline expectations centered around“zero non-value add”:4No wasted time for idle inventory4No wasted material4No wasted effort in rework or scrap4No wasted time for idle resources
25、4No wasted motion4No wasted support4No wasted time in unnecessary activitiesProcess DiagnosisDevelop a road map for the design of the process 4Develop detailed Process Flow Charts:(using a mechanical assembly drawing or an actual unit and the BOM)4Material point of view4Operator point of view birds
26、eye view motion,time,effort(physical operations)Process DiagnosisRemember to map the following 4Chart any other functions that are related to the process:4FVT4ESS4Hi-Pot45DX4Takaya4Pack-Out4Kit-Prep4Rework Area4Reject material on the line4Etc.Process Diagnosis-MOSTSurvey 4What is MOST?4Have you used
27、 MOST at your plant?4If yes,what value did it provide?Maynards Operation Sequence TechniquesProcess Diagnosis-MOSTWhy use MOST?4MOST will enable the operator to combine the operator and material flow charts into one series of assembly steps.4To determine TAKT time of each product 4When developing a
28、MOST analysis,what should we consider?Zero non-value add baseline Space allocated Process flow chart Flexible,scalable&modular manufacturing line Zero waste Materials handling&management systems Standard Jabil machinery&equipment etcProcess Diagnosis-MOSTAnalysis and Diagnosis Why is it necessary?4V
29、alue Stream Mapping 4Process Failure Mode and Effect Analysis to assure that the designed operational assembly sequences steps have the least amount of waste can be used as a tool to measure the gap between the proposed process steps and their potential performance it will enable an analysis of proc
30、ess failures early enough in the design processLine Design ApproachAs a group lets discuss 4Why do we need to analyze and process a large quantity of information for a simple line design?easier to allocate costs make changes&moves incorporate the flexibility,scalability&modularity avoid waste and NV
31、A focus on processes ability of IEs to analyze data,which separated us from other functional Line DesignIn Teams So once we have determined our TAKT time based on MOST,the forecast,the previous baseline and information 4What do we do next?4How?4List the steps?4What key elements would you include in
32、your instructions to your Engineers to interpret and organize this information?You have 15 minutes Breakout Exercise:Line Design 4What do we do next?4How?4List the steps?4What key elements would you include in your instructions to your Engineers to interpret and organize this information?Whats Next?
33、How?Key Steps Key ElementsLine DesignTo summarize Once you have the TAKT time then:4Develop a rough layout4Manipulate and adjust for good fit and function4Challenge each individual layout with the design Philosophy:4“Is the line designed a simple system that is flexible,scalable and modular in a cos
34、t effective manner with minimum waste for our customers?”4Do a cost justification to narrow the gap4Develop the final layoutLine Design4Line Design MethodologyLine DesignLets review the final steps 4Process Implementation 4Process Monitoring subsequently,a project plan should be developed to detail
35、the sequence of event and their respective durations once the project has been implemented,all that is left to do is to monitor the performance of the process or operation to ensure a closed loop processCritical Success Factors As a group 4What are the critical success factors to an optimal line des
36、ign at Jabil?be a simple system that is flexible,scalable&modular in a cost effective manner with minimum waste for our customer satisfy the customer needs other functional groups are informed and educated zero waste maximum value addQuestionnaire1.The IE approach to line design at Jabil is to devel
37、op a simple system that is flexible,scalable and modular in a cost effective manner with minimum waste for our customers2.Flexibility for Jabil means being able to re-deploy all of the equipment to existing and future customers 3.The IE must design a manufacturing line that meet the customers want i
38、n order to win the business4.Product mix,forecast,customer expectation,assembly methods,process flow,product life cycle,production build plan,floor space,etc are some of the key information needed for process mapping5.The optimal line design is centered around a vision of zero waste and zero non-val
39、ue addTrueFalse Questionnaire6.We always use the“Material Process Flow Chart”to allow us a detailed look at what physical operations are required in the process7.“MOST will enable the IE to combine the assembly sequence steps,describe in the materials and operator process flow chart,into one sequent
40、ial series of value added steps as the basic for initial line design layout8.“Value Stream Analysis”assure that the operational assembly sequence steps designed has the least amount of waste9.The overall product life cycle of the individual customers at Jabil is normally rather short,we should not s
41、pend too much effort to gather and analyze large quantity of data for a simple line design10.The line design process is never complete;it is rather a continuous improvement processTrueFalse Question?Comment?Feedback?Suggestion?THANK YOU49、静夜四无邻，荒居旧业贫。5月-235月-23Tuesday,May 16,2023410、雨中黄叶树，灯下白头人。15:0
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