Ghirann The Basics of Self-Balancing Processes

True Lean Continuous Flow
1. Auflage 2012
ISBN: 978-1-4665-5258-6
Verlag: Taylor & Francis
Format: PDF
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 108 Seiten

Self-Balancing is not just a tweak or change to assembly line balancing, but a completely transformed method for achieving continuous flow. Among the reasons you should try Self-Balancing is that you can expect a productivity improvement of at least 30 percent—with improvements of 50-60 percent quite common.

Using a well-tested method for successful improvements initiated by the author, The Basics of Self-Balancing Processes: True Lean Continuous Flow is the first book to explain how to achieve continuous flow in both simple and complex manufacturing environments. It describes how to recognize and resolve weak links to ensure continuous flow in your manufacturing operations.

The book offers rules, tools, and guidelines to help you not only solve problems at the root, but even eliminate them before they start. It reviews the shortcomings of traditional assembly line balancing and walks readers through the new paradigm of Self-Balancing.

The text includes a comprehensive overview that demonstrates the power, flexibility, and breakthroughs possible with this method. Offering solutions to the shortcomings associated with standard line balancing—including inventory buffers, variation, and operator pace—it provides you with the tools and understanding required to deal with batch and off-line processes, debug your line, arrange your parts and tools, and design your own Self-Balanced cells.
Watch Gordon Ghirann discuss how his book can increase the productivity of your business.
http://www.youtube.com/watch?v=yte0622XbcI&feature=youtu.be

Zielgruppe

Plant and quality improvement managers and supervisors, industrial, system, and manufacturing engineers, and engineering instructors and students.

Autoren/Hrsg.

Ghirann, Gordon

Fachgebiete

• Wirtschaftswissenschaften Betriebswirtschaft Bereichsspezifisches Management Produktionsmanagement, Qualitätskontrolle

Inhaltsverzeichnis

Conventional Assembly Line Balancing
Paced Lines
Manual Assembly Lines
Level Loading

Shortcomings of Level Loading
Artificially Balanced
WIP Buffers
Slowest Operator/Station Sets the Pace
Variations in Yield and Cycle Time
Absent Operators
Inflexible, Difficult-to-Adjust Output
Silo Mentality
Repetitive and Monotonous Work for the Line Workers
Moving Beyond Level Loading

A New Paradigm
Conditions for Continuous Flow
Self-Balancing
Rules to Standardize Self-Balancing
Rule 1: Keep Building Progressively Until Someone Pulls from You
Rule 2: When the Downstream Operator Pulls from You, Walk Upstream to the Next Operator and Pull from Them
Rule 3: If You Catch Up to Someone When Moving Downstream, Wait
Rule 4: Don’t Leapfrog; Everyone Stays in Their Position
Rule 5: Communicate, Communicate, Communicate!
Dealing with Fumbles
Standard Conditions for a Fumble
Nonstandard Conditions for a Fumble
Fumble Rules
Rule 1: Encountering a Fumble When Moving Upstream
Rule 2: Encountering a Fumble When Moving Downstream
Rule 3: Returning to a Fumble

Batch and Off-Line Processing
Curtain Operations
Backbench
In/Out Tray
Guidelines and Rules for Backbench Operations
Rule 1: Frontline Operators Leave the Line to Perform Backbench Operations on Demand
Rule 2: Operators Communicate When Leaving for the Backbench
Rule 3: Reenter the Frontline in the Same Position
Types of Loading and Unloading

Subassembly Feeder Lines
Rules for Self-Balancing Subassembly Feeder Lines
Rule 1: Going Down the River
Rule 2: Going Up the River
Rules for Subassembly Feeder Line Operators
Rule 1: When Frontline and Feeder Line Are Synchronized
Rule 2: Encountering a Fumbled Subassembly

Debugging the Line
Standard Work
Bottlenecks
SWIP Inventory
SWIP Increasing
SWIP Decreasing
Additional Debugging
Horizontal Arrangement of Parts and Tools
Benefits and Potential Disadvantages of Horizontal Part and Tool Presentation
Additional Rows of Parts for Mixed-Model Lines
Quick Product Changeover of a Cell

Cell Designs
Cell Design Considerations
Safety
Walking Distance
Part-Travel Distance
Cell Layouts
Basic Cell Shapes
Cells with Off-Line Processing
Station Setup
Right-Sized Stations
Vertical Space
Standing Height
Standing Surface

Conclusion

Index

Über Autor(innen)

Gordon Ghirann received his B.S. in Mechanical Engineering from Cal Poly, San Luis Obispo. He began developing the self-balancing methodology in 1998, working at and with several companies, products lines, and processes around the world, sharing, consulting, and teaching along the way. Gordon has been a regularly featured presenter of Workshops at the Association of Manufacturing Excellence (AME) conference. He currently resides in California. Visit www.self-balancing.com for more information.