ppt 40573 Lean Cell Manufacturing History and the Modern ERP Software Package in Globalization
Using ERP in a Lean Manufacturing environment
description
Transcript of Using ERP in a Lean Manufacturing environment
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Using ERP in aLean Manufacturing environmentAndy BarnesOperations ManagerSnell & Wilcox Ltd
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Outline AgendaAbout S&WSupply Process ImprovementMFG Pro in a Lean Environment
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About Snell & Wilcox
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History1973: founded by Roderick Snell and Joe WilcoxTo focus on the preservation and improvement of the television image1988: Joe Wilcox retires, 24 employees1993: Introduction of Alchemist with Ph.C1994: Acquired CEL Ltd1996: MPEG (Moving Picture Experts Group) activities began1999: MXF (Material Exchange Format) work starts2001: Acquired Post Impressions and PSP2005: Turnover ~36m, 350 employees worldwide
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Products- IQ Modular
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Products- Switchers
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Award winning recordFour technical EmmysPhase correlation motion compensation (Ph.C) - the key to superior standards conversionPrefix MPEG pre-processing - saves storage and transmission costsDEFT 3:2 cadence detection and repair - improves Hollywood workflow efficiency HD up and down conversion - for flexibility in production and broadcast
Many other awards:Eight Queens AwardsFirst to win two IABM Peter Wayne Technology and Innovation Awards
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Customers including...
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LocationsSouthleigh ParkHQ, R&D, ManufacturingSouthleigh Park, Havant
R&D, ManufacturingSaffron Walden
R&DNewbury, Liss, Montreal
Sales and ServiceUK, France, Germany, Russia,USA, Hong Kong, China, Japan, India, Lebanon
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Supply Process Improvement
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Historical ProcessForecast driven batch build process (push)Long lead times ~4-6wksPoor levels of customer service - OTD ~55%High levels of inventory - stock turns ~4/annumQuality issues highlighted late in build process - Rework
- ObjectiveImprove historical levels of on timedelivery, lead time and quality to worldclass levels:S&WTargetOn time55%>98%Response4-6 wks
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Time for Change- Spring 2004Established a full time multi-functional teamCapability through intensive trainingExternal support - Cranfield ConsultantsPilot project using simple product family - Kudos+
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Types of WasteTheSevenWastesOtherCommonWastes
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Value Stream Mapping- 1U Gateway Card
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BatchesSpaceTransport / handling problems (damage)Time to make batch - some of which arent needed
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The Problem with BatchesSMTRobotasFlow SolderElectricalAssembly
Mechanical Assembly
TestSoak
Distance travelled between remote silos = 470mEach silo making batches independentlyDelays and difficult to align production to actual orders customer lead time 4-6 weeksPushing Batches Through Cycle time to make whole batch not just what customer ordered Waiting for other batches Pinching from one batch to fulfil more urgent order High inventory everywhere Response time = time for complete batch to move through complete process, queuing behind other batches
InventoryCustomer Lead Time
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Pull / FlowSMTRobotasFlow SolderCell: Elec/Mech/Test/Soak
Distance travelled between shared resources and cell = 70m (85% reduction)Customer lead time down to final process time
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Work Content
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Actual Cell layout
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Before AfterClutteredPoor LightingPoor VentilationSearch for tools & partsOrganisedBrightCleanEverything to hand
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PCB Before
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PCB After
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Test Before
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Test After
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Kudos+ WorkstationParts for the buildBuild InstructionClean & clear place to build the product
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Build InstructionsNumbers in build instruction match those on the part bins
MANUAL No
DESCRIPTION
1U Rear Panel Interconnect PCB
ASSY No.
SAAN RCIC1U2Z
LOCATION
ZCELLK A
DATE
23/08/04
10
RMK7 P2RA
39
RMK0 07
31
RMK6 P10
40
RMK0 19
39
EMBED Word.Picture.8
31
40
STEP 2
Solder components to PCB in the following order:-
Item Cct Ref
CN10
CN9
31CN8
40CN7
10
_1154781847.doc
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2 Bin Kanban SystemNumbers in build instruction match those on the part bins
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Signal to BuildEmpty space is the signal to build
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Bin ReplenishmentRefilled bins are placed here by storesEmpty bins are placed here for stores to collect
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ATE Test JigProduct can be tested by the person who made it in the cell
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Benefits - Kudos+ KPIs
Chart1
38082380820.5
38089380890.6
38096380960.4
38103381030.67
38110381100.64
38117381170.67
38124381240.75
38131381310.47
38138381380.5
38145381450.5
38152381520.57
38159381591
38166381661
2691
20111
20221
15301
19161
17260.85
14340.89
19180.89
30240.96
18300.87
15200.95
12200.95
14151
12291
16171
18281
15261
13301
13311
10181
11161
11300.91
11141
LEAD TIME
NO. OF ITEMS
ON TIME DELIVERY
WEEK COMMENCING
LEAD TIME (DAYS) / NUMBER OF ORDERS
OTD %
KUDOS+ PRODUCT CELLWEEKLY KPI'S - OUTPUT
DATA
MFG7.15.8.12?
WEEKON TIMELEADNO. OFINVENTORYINVENTORY
COMMENCINGDELIVERYTIMEITEMSACCURACY
5-Apr-0450%
12-Apr-0460%
19-Apr-0440%
26-Apr-0467%
3-May-0464%
10-May-0467%
17-May-0475%
24-May-0447%
31-May-0450%
7-Jun-0450%
14-Jun-0457%
21-Jun-04100%
28-Jun-04100%
5-Jul-04100%269
12-Jul-04100%2011
19-Jul-04100%2022
26-Jul-04100%153095%1,000
2-Aug-04100%1916
9-Aug-0485%1726
16-Aug-0489%1434
23-Aug-0489%1918
30-Aug-0496%3024
6-Sep-0487%1830
13-Sep-0495%1520
20-Sep-0495%1220
27-Sep-04100%1415
4-Oct-04100%1229
11-Oct-04100%1617
18-Oct-04100%1828
25-Oct-04100%1526
1-Nov-04100%1330
8-Nov-04100%1331
15-Nov-04100%1018
22-Nov-04100%1116
29-Nov-0491%1130
6-Dec-04100%1114
13-Dec-04100%1335
20-Dec-04100%11
27-Dec-04
3-Jan-05100%1645
10-Jan-05100%2250
17-Jan-05100%1734
24-Jan-05100%716
31-Jan-0590%1624
7-Feb-05100%4228
14-Feb-0563%2037
21-Feb-0592%2221
28-Feb-05100%1511
7-Mar-0570%3362
14-Mar-05100%1626
21-Mar-0587%2023
28-Mar-05100%2736
4-Apr-05100%3118
11-Apr-05100%1516
18-Apr-05100%821
25-Apr-05100%1416
2-May-05100%1024
9-May-0598%6139
16-May-05100%1641
23-May-05100%1121
30-May-0594%1018
6-Jun-05100%7434
13-Jun-05100%3726
20-Jun-05100%1025
27-Jun-05100%1122
4-Jul-05100%1023
11-Jul-0583%1824
18-Jul-0586%2517
25-Jul-0596%1243
1-Aug-0593%926
8-Aug-05100%5134
15-Aug-05100%1843
22-Aug-0585%1030
29-Aug-05100%189
5-Sep-0564%2518
12-Sep-0544%1215
19-Sep-05100%1215
26-Sep-0510%1234
3-Oct-0510%1234
45%1023
50%515
GRAPH #1
GRAPH #1
38082380820.5
38089380890.6
38096380960.4
38103381030.67
38110381100.64
38117381170.67
38124381240.75
38131381310.47
38138381380.5
38145381450.5
38152381520.57
38159381591
38166381661
2691
20111
20221
15301
19161
17260.85
14340.89
19180.89
30240.96
18300.87
15200.95
12200.95
14151
12291
16171
18281
15261
13301
13311
10181
11161
11300.91
11141
&A
Page &P
LEAD TIME
NO. OF ITEMS
ON TIME DELIVERY
WEEK COMMENCING
LEAD TIME (DAYS) / NUMBER OF ORDERS
OTD %
KUDOS+ PRODUCT CELLWEEKLY KPI'S - OUTPUT
GRAPH #2
GRAPH #2
10000.95
38201
38208
38215
38222
38229
38236
38243
38250
38257
38264
38271
38278
38285
38292
38299
38306
38313
38320
38327
38334
38341
38348
INVENTORY
INVENTORY ACCURACY
WEEK COMMENCING
INVENTORY
INVENTORY ACCURACY %
KUDOS+ PRODUCT CELLWEEKLY KPI'S - INVENTORY
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Extra BenefitsImproving the process has uncovered more opportunities that were hiddenHelped identify key training requirements within the cellImproved floor space utilisationNew Kanban philosophyTransactions reducedContinuous improvement culture developing
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Benefits - Reduced WIP132 Units~400 Each52,800
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Benefits - Space274.125m220% Overall Reduction
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Lean Projects RoadmapKudos+ cell - Completed July 04IQ Modular - 80% completeBox build cellPCB build & test cellBox configuration & conformance test cellKahuna cell - 90% completeOther product cells - December 05Surface Mount line - 2006
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MFG Pro in a Lean Environment
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History1994: Introduced Release 7.1 on a UNIX operating system1996: Upgraded to 7.42002: Upgraded to eb2005: Still bloody character screens!
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Supply Process- Pre LeanMRP Planned Ordersdetermine what weACTUALLYPurchase (POs) andManufacture (WOs)SOPMPSMRPWORKORDERSPURCHASEORDERS
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Supply Process- Post LeanMRP Planned Ordersdetermine what weMIGHTPurchase (VS)andManufacture (CRP)
Demand Pull (SO,Kanban, Faxban)determines what weACTUALLY Purchase& ManufactureSOPMPSMRPCRPVENDORSCHEDULES
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Supply Process- Vendor Schedules
VS00005
Delivery Schedule
TOBY ELECTRONICS LTD
Deliver To:
TOBY ELECTRONICS LTDSnell & Wilcox Ltd
BEAUMONT ROAD IND ESTSouthleigh Park House
BANBURYEastleigh Road
OXONHavant
OX16 1TUPO9 2PE
GREAT BRITAINGREAT BRITAIN
Purchase Order:VS00005
Week Commencing...
ItemFab AuthRaw AuthPrior17/10/0524/10/0531/10/0507/11/0514/11/0521/11/0528/11/0505/12/0512/12/0519/12/0526/12/0502/01/0606/02/0606/03/0603/04/0601/05/0605/06/0603/07/0607/08/06
RMG9 ELM5/04000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMG9 ELM5/10000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 10WMTSW105000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 10WMTSW110000F0F22F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 20017AR-16G2000F0F500F1000P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 24WBOXED000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 399R/A000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 BBS10000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 HW0511GS000F0F450F0P900P1584P744P0P0P336P336P0P0P0P0P0P0P0P0P0P
RMK0 QTE02003000F0F278F0P0P0P144P72P0P0P180P0P0P0P0P0P0P0P0P0P
RMK0 QTE02005000F0F100F96P0P0P0P0P0P0P0P198P0P0P0P0P0P0P0P0P
RMK0 TSW1914TD000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 17000F0F0F0P77P28P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 1712001SD000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 1712002SDLC000F0F0F0P0P0P0P36P0P0P70P0P0P0P0P0P0P0P0P0P
RMK1 1713001SD000F0F13F0P0P8P0P6P0P0P12P0P0P0P0P0P0P0P0P0P
RMK1 1713002SDLC000F0F0F0P0P17P0P0P0P0P24P0P0P0P0P0P0P0P0P0P
RMK1 19000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 20000F0F4F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 BSW-10204-G-S000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 M22-6120822000F0F16F0P0P0P1P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 QSE02001000F0F0F35P0P240P0P240P0P240P176P0P0P0P0P0P0P0P0P0P
RMK1 SFML130T2S000F0F39F0P0P0P48P0P16P0P0P0P0P0P0P0P0P0P0P0P
RMK1 SQT11203FD000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 SSQ12001000F0F0F0P0P4P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 SSQ13201000F0F0F0P0P1P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK1 TFML13002000F0F206F0P68P124P0P68P0P0P0P0P0P0P0P0P0P0P0P0P
RMK6 SFM105-01000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 14000F0F29F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 16000F0F50F0P0P0P25P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 20000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 24/.3000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 28000F0F280F168P168P238P154P168P196P0P210P0P0P0P0P0P0P0P0P0P
RMK8 32.6000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 6PDIL000F0F0F345P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK8 8PDIL000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMKA 24/.3SMT000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMKA FTSH10501000F0F500F250P375P0P250P250P0P250P375P0P0P0P0P0P0P0P0P0P
RMKA TFM10522S000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMKA TFM12022S000F443F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMKA SFM12002S000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMW4 7642430A000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK3 RCAJACK000F0F0F0P0P0P21P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK0 34000F0F0F0P0P12P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
RMK5 16000F0F0F0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P0P
Sheet2
Sheet3
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Supply Process- CRP
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Supply Process- Sales Order ProcessingPRE LEAN MPS ATP
POST LEANFinite Capacity Scheduling
Sheet1
FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41539 - Line 2
FGADG 3768050AARC20:20S ASPECT RATIOSO41345 - Line 1
FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41274 - Line 11
FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41274 - Line 11
FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41284 - Line 1FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41243 - Line 3FGACZ 3598000BMACH:1 PHASE4 Msc MOTIONSO41270 - Line 1FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41403 - Line 2FGADG 3768050AARC20:20S ASPECT RATIOSO41506 - Line 1
FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41284 - Line 1FGACU 3548310BTBS180AV ADVANC TIMEBASESO41202 - Line 8FGACZ 3598000BMACH:1 PHASE4 Msc MOTIONSO41270 - Line 1FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41402 - Line 2FGADG 3768050AARC20:20S ASPECT RATIOSO41506 - Line 1
FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41229 - Line 2FGACU 3548310BTBS180AV ADVANC TIMEBASESO41202 - Line 8FGACZ 3598000BMACH:1 PHASE4 Msc MOTIONSO41270 - Line 1FGAN IQH1S-RC-AP-BMOD-1U FRAME+ACTIVE F/P+SO41326 - Line 1FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41329 - Line 10
FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41158 - Line 2FGACU 3548300BTBS180 ADVANCED TIMEBASESO41162 - Line 7FGACZ 3598000BMACH:1 PHASE4 Msc MOTIONSO41270 - Line 1FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41321 - Line 13FGAN IQH1S-RC-BMOD-1U FRAME+BLANK F/P +SO41299 - Line 2
FGACZ 3598300BCVR250 ACTIVE F/P 10-BITSO41273 - Line 1FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41158 - Line 2FGACU 3548500BNRS70 ACTIVE F/P 1RUSO41162 - Line 6FGACU 3548410BTBS185AV ADVANC TBC WITHSO41545 - Line 1FGACZ 3598000BMACH:1 PHASE4 Msc MOTIONSO41270 - Line 1FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO41321 - Line 13FGAN IQHSBOXRCAPBMOD-1U REMOTE SHOEBOXSO40871 - Line 24
24/10/0525/10/0526/10/0527/10/0528/10/0531/10/0501/11/0502/11/0503/11/0504/11/05
MTWTFMTWTF
Sheet2
Sheet3
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Supply Process- Material TransactionsPRE LEANMRP Planned Orders Report (23.12)Check for shortages (13.8.18)Firm Plan Work Order (16.1)Release Work Order (16.6)Kit Work Order (16.10)Make Product / AssemblyReceipt Work Order into stock (16.11)
POST LEANMake Product / AssemblyAdvanced Repetitive Backflush Product / Assembly (18.22.13):Cumulative Work OrderConsume materialsConsume labour @ standardReceipt into stock
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ANY QUESTIONS?Thank you
High volume product range low costInstalled in broadcast studiosLow volume high costStudiosLive eventsBrief overview of Kudos + project Showing new KPIs achieved through the change process, from forecast batch build to customer demand pull manufacture.Productivity gains through the use of standard operating procedures (photographic build documents)Increased control of raw material through KanbansPhoto showing PCB workstation in the forecast batch build culture.PCB workstation in the manufacturing cellCleanClearAll raw materials required for product at the point of use (Kanbans)Photo showing test workstation in the forecast batch build culture.Not easy to see where product is or where it flowsTest workstation in the manufacturing cellCleanClearDedicated place for productEach foam used to hold productAfter the Kudos+ project all these foam were not requiredThe one of saving of work in progress was ~52KThere was a considerable amount of floor space saved as wellPhoto of first floor test showing the space generatedCurrently a 20% reduction in manufacturing space