LEAN Basic Tools Concepts - Part 6

PROCESS BALANCING

Purpose: To balance work across different sub processes
When to use it : When lead time is a problem
How to do it
•Minimize movement
•Stabilize lead time before trying to minimize it
•Maximize resource efficiency
•Minimize number of process steps
•Balance tasks/labor across process steps
•Maximize space utilization
•Minimize Non-Value Add activities (conveyance, standby and motion wastes)
•Minimize the need to rebalance as demand requirements change
•Minimize volume variability (combine product category demand)
•Maximize flexibility for product introductions and discontinuations
•Use training and continual reinforcement to maintain gains

WORK CELL OPTIMIZATION
Purpose - To reduce the time needed to complete a task or set of tasks and reduce mistakes
When to use it - To reduce inefficient workflow (i.e. too much movement of material and/or people)
How to do it - Will never get the design perfect the first time – get it in place then use operator feedback and continuous improvement

Phase 1: Pre work
•Stabilize lead times throughout the entire process
•Eliminate part shortages
•Make sure the entire process is meeting customer requirements (demand, quality)

Phase 2: Redesign a Work Cell
•Design (layout, flow) for multiple machines or steps per operator, but overstaff at first so that CTQ’s are not compromised
•Decide where raw materials and Work In Process (WIP) inventory will be located
•Select a cell design (next slide) and put into place
•Apply operational improvements to reduce batch sizes
•Apply process balancing (see slide 43) to smooth task times
- Goal is to get to a batch size of one which is termed continuous flow manufacturing or one piece flow