Jit tm-007-c1.0-leveling.ppt[1]

PRIVATE/PROPRIETARYJIT-TM-007-C1.0-Leveling – of 17

APS Training ModuleJIT – Leveling

Autoliv14-April-2006

JIT–TM-007-C1.0

PRIVATE/PROPRIETARYJIT-TM-007-C1.0 -Leveling– of 17

Autoliv

Quality assurance

Quality methods

Six Sigma

Standards

Pull system

Safety & Ergonomy

Don’t judge, don’t blame !

Flexibility & Motivation

Discipline to standards

Continuous improvement

Process & Result

Customers

Company Employees

Society

Quality first

ProfitabilityCompetitiveness

Satisfaction

Employee involvement

Team work 5S Muda elimination TPM

Just in time

Leveling & Capacity

Line concepts

Continuous flow

Takt time

Frequent deliveries

Leveling & Capacity


Why this training

During this training you will learn:• What is the purpose of leveling?

• What are the three components of leveled production?

• How do we level production?

• What are the benefits of leveling?


Satisfy customer demand and create stable production while continuously

improving standards

Give the customers:

Purpose of Leveling

• What they want • When they want it• In the quantity they want


Contract Leveling

Monthly activity Daily activity

Rail Management

Hourly activity

Leveling


Leveling

Leveling has 3 components:

• Volume

• Variety

• Time

When demand is level, it gives you an opportunity to effectively plan your Manpower, Material, and Machines.

Low Demand

Levelled Production

Without leveling, your capacity must equal the

Highest Demand Balanced Demand

PRIVATE/PROPRIETARYJIT-TM-007-C1.0-Leveling – of 17

Monthly Need

Ref A

100 boxes

Ref B

200 boxes

Ref C

300 boxes

Level1

Level1

20 pallets

40 pallets

60 pallets

Réf A

Réf B

Réf C

MonthOnce a month

each reference

Level2

Level2

10 pallets

20 pallets

30 pallets

10 pallets

20 pallets

30 pallets

Réf A

Réf B

Réf C

MonthMore than once

a month of each reference

Level3

Level3

1 palletRéf A

Réf B

Réf C

Day2 pallets

3 pallets

Once a day

each reference

Level4

Level4

1 pallet

1 pallet

1 pallet 1 pallet

1 pallet 1 pallet

Réf A

Réf B

Réf C

Day All references at least once a day standard batch (equal quantity)

Réf A

Réf B

Réf C

1 box

1 box 1 box

1 box 1 box 1 box

1 box

1 box 1 box

1 box 1 box 1 box

DayReduce size of

batch at the minimum : box, or even single

product...

Level5

Level5

What is Leveling?


Leveling

Production every WEEK

Stock averageDelivering every DAY

WHY Level 5 (small lot) is better than Level 1 (large lot)?


Leveling

Production every 2 days

Delivering every DAY

Stock average

Production every WEEK

Stock averageDelivering every DAY

WHY Level 5 (small lot) is better than Level 1 (large lot)?


500 A30 B260 C

400 A 30 B360 C

390 A80 B320 C

210 pieces lost !

Breakdown !

BA C

500 400100

A C A C A B A C A C

100 100 100 100 100 100 100 100 100 100

ACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACAC

Batch of 10

500 A100 B400 C

500 A100 B400 C

500 A100 B400 C

500 A30 B260 C

400 A30 B360 C

390 A80 B320 C

100%30%65%

80% 30%90%

78%80%80%

- Qty is not good+ Every customer has 80% of need

WHY Level 5 (small lot) is better than

Level 1 (large lot)?

Leveling


BA C

500 400100

A C A B A C A C A C

100 100 100 100 100 100 100 100 100 100

ACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACACAACABACAC

Batch of 10=> Planning can easily be changed for productıon10:00 am

Customer Emergency

C CCCCCCC

=> Planning can not easily be changed for productıon

C

WHY Level 5 (small lot) is better than

Level 1 (large lot)?

Leveling


HOW : ( OUTPUT )AMO : Logistic

AMO : Production

AMO : Production Engineering

AMO

- daily quantity agreement per family and flexibility inside each family- non chaotic supplier demand

- daily quantity agreement per day- Stable number of operators needed every day for the whole month- TAKT TIME for each production line

- Line availability for technical improvement

- Non chaotic activity- Monthly action plan- Team Building

Leveling


HOW to define the right level ? • What is your criteria for batches ?

→ Change over time ?

→ Criteria with direct labor impact ?

→ Replenishment criteria ?

→ Quality concerns ?

→ Packaging size

Production line must run according to

Takt time, with the best efficiency to

meet customer satisfaction in Quality,

Cost and On Time Delivery

Leveling


HOW ?• Define a matrix with reference and criteria

Leather Foam with switch without switchRef A x xRef B x xRef C x xRef D x xRef E x xRef F x xRef G x xRef H x xRef I x xRef J x x

NISSAN X31B

Family 1

Family 2

Family 3

Family 4

Logistic Criteria Production Criteria

Supply chain Impact :

- Levelling of material incoming ==> reduce the line stoppage due to lack of material

Productivity Impact :

- production under control - stable number of operators

Leveling


HOW ?• Define the batch size

(as small as possible)

batch size

Number of

batch/day 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4

Ref ARef BRef CRef D LevellingRef ERef FRef GRef HRef I

Family 4 Ref J 320 3 J J J J J J

D DC

FF

504

270

48

Family 1

Family 2

Family 3

100

5

3

1

BD D B C

F F E

G

ContractQty/day

G

E

A A

• Change over are forecasted, production is becoming predictable

• Logistic can put any reference related to a family within a family batch

• Level batches in the

Heijunka board

Total 12 batches 1 2 3 4 5 6 7 8 9 10 11 12

Leveling


• Production under control

• Change over under control

• Planning flexibility within a family

Leveling Benefits


Why this training

Can you answer these questions:• What is the purpose of leveling?

• What are the three components of leveled production?

• How do we level production?

• What are the benefits of leveling?

Jit tm-007-c1.0-leveling.ppt[1]

Business

Transcript of Jit tm-007-c1.0-leveling.ppt[1]