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TPS Cells and Manufacturing System Comparisons T. Gutowski

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Title: TPS Cells and Manufacturing System Comparisons T. Gutowski


1
TPS Cells and Manufacturing System ComparisonsT.
Gutowski
  • Ref
  • J T. Black Factory with a Future McGraw-Hill
    1991, Chapters 2 4
  • The Monument of Monuments from Lean Thinking,
    Womack Jones 1996
  • 5 homework problems due Nov 13th

2
Topics
  • Operation of cell Standard work
  • Increase in production rate
  • Video of cells
  • L, l W for cell LlW
  • Design of cell
  • Comparison with job shop and flow line

3
Cell Features
  • Synchronized, sequential production
  • Operator decoupled from individual machines
  • Operator integrated into all tasks
  • Goal single piece Flow
  • Best with single cycle automatics, but can be
    done manually too

4
Machining Cell
Operator moves part from machine to
machine (including decouplers) by making
traverse around the cell.
Video
5
Machining Cell
Walking segments - 10
Manual (Sec) Walk (Sec) Machine (Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3 60
G 15 3 60
F.I. 19 3 3
Totals MW 153 490
6
5
7
8
4
9
3
10
2
1
6
Machining Cell
Parts in the cell 14
7
8
9
6
Manual (Sec) Walk (Sec) Machine (Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3 60
G 15 3 60
F.I. 19 3 3
Totals MW 153 490
10
11
5
14
12
4
13
3
2
1
7
Standard Work for Cell
Cell produces one part every 153 sec Note
machine time Max (MTj) lt cycle time CT i.e. 120
lt 153
8
To increase production rate add 2nd worker
Manual (Sec) Walk (Sec) Machine (Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3 60
G 15 3 60
F.I. 19 3 3
Totals MW 153 490
Work 1 77
Work 2 76
WORKER 2
WORKER 1
9
What is the production rate for this new
arrangement?
  • Check max(MTj) lt CT
  • Worker 1 70 lt 77
  • Worker 2 120 gt76
  • One part every 120 seconds
  • Can we shift work off of the HM to reduce the
    cycle time?

10
Manual (Sec) Walk (Sec) Machine (Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120 80
VM1 20 3 70 80
VM2 20 3 60 90
G 15 3 60
F.I. 19 3 3
Totals MW 153 490
Work 1 77
Work 2 76
WORKER 2
WORKER 1
11
Standard Work for Worker 2
Cycle 1
Cycle 2
Operator waiting On machine
12
What is the new production Rate?
  • Check max(MTj) lt CT
  • Worker 1 70 lt 77
  • Worker 2 90 gt 76
  • Hence Worker 2 will be waiting on Vertical
    Mill 2

13
What is the new production Rate?
  • The new production rate is
  • one part every 90 sec
  • Pro and Cons Worker idle, cant speed up by
    adding additional worker
  • Design for flexibility make
  • Max(MTj) lt CT/2

14
Alternative solution add 2 HMs
Manual (Sec) Walk (Sec) Machine (Sec)
Raw 3
Saw 15 3 60
L1 10 3 70
L2 12 3 50
HM 12 3 120
VM1 20 3 70
VM2 20 3 60
G 15 3 60
F.I. 19 3 3
Totals MW 153 490
Work 1 77
Work 2 76
A
B
WORKER 2
WORKER 1
15
What did you think of the operators job in the
video? See BS Video
Seeta cave, Ellora, India
16
TPS Cell and Littles Law
  • L l W, we know L and l, what is W?
  • Define System Boundaries
  • Follow part around the cell
  • Single operator case

17
Machining Cell
Number of round trips 13
7
8
9
6
10
11
5
Saw 315 153
1 decoupler 1.5 153
L1 1.5 10 153
. .
Grind 1.5 15 153
Manual and walk 193 out
150 153X131989
12
4
13
3
2
1
  • 1989 150 2139

18
By Littles Law
  • L (13 1) X 150/153)
  • 13 X (3/153) 13.98
  • rate, l 1/153
  • W 153 X 13.98 2139

Homework 1 Determine L,l W For the 2 operator
Systems
19
Designing a cell for the Rod Support Goal
one part every 2.5 minutes
  • Material Aluminum extrusion
  • Tolerance 0.005, except for the two 0.50
    radius corners which have 1/64

20
Cellular Layout (One operator)
Cold Saw
Radial Arm Drill Press
Drill Press
Belt Sander
21
Cellular Layout (One operator)
Note Times in minutes
22
Cellular Layout (One operator)
RA Drill Press .47.05/.24
Walking time
23
Standard Work for Rod Support Cell
Note Times in Seconds
24
2.810 Homework
  • 2 Increase the production rate for this cell to
    one part every minute
  • 3 After reading The Monuments of Monuments,
    answer
  • a) Calulate the production rate for each system
  • b) How many cells are required to replace the
    Blohm grinder?

25
Other Layouts
Job Shop
Flow Line
FMS
26
Job shop (Small quantities, Aluminum block)
27
Job shop (Large quantities, Aluminum extrusion)
28
CNC production, aluminum block
29
Flow shop (Unbalanced work load)
30
Flow shop (Improved work load)
31
Comparison
32
Cost Calculation without considering Inventory
holding cost
33
Cost for increasing production volume
C F V N
34
Cost for increasing production volume
35
Results
System Number of Parts Quality tracking Flex- ibility
JS1 500- 1000 -
FS2 3000-50,000 -
cell gt50,000

36
2.810 Homework 4 design cell for this part at
one part every 7 minutes, 5 redesign for one
part every 4 minutes
Dimensions in inches, surface in micro-inches
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