CIMS

GBC
IE

E-mail: zw.niu@163.com
13302105673
CIMS

CIMS

CIMS

Lean

5S
Production
D
C

Material to Store

Previous
Process

Production Pull

CIMS

Buffer or Store

P
A

JIT

Product to User

Subsequent
Process

Withdrawal Pull

TPS
TPM


Individual Efficiency

Individual Lot Production

Flow Production in U-Line

Total Efficiency

CIMS

VS.
Non-Flow
Part
A
Part
B
Part
C
Part
D
Part
E

CIMS

Flow
Parts
A&C

Parts
B&D

Part
E

198514
5500

Lean Production

CIMS

1896
13
1908485

1914

1928
120

1896

1930

1933

1936AA
1937
4000

40
CIMS

1950
89

1950
10

321982
11.5 54.6

CIMS

1973

CIMS

TPS

VCD
40

3PPM6

CIMS

JIT

LCIA

SMED

LAYOUT

IE
5S

CIMS

CIMS

WTO

CIMS

WTO

CIMS

(1)(Products)
(2)(Inventory)
(3)(Cost)
(4)(Quality)
(5)(Maintenance)
(6). (Delivery)
(7).(Safety)

CIMS

CIMS

CIMS

CIMS

(TPS)
JIT()

CIMS

TPS

CIMS

2
101000

101200
81000

CIMS

2
3
4
5
CIMS

CIMS

9010

9010

CIMS

!!!

CIMS

(b)

(c)

(d)

CIMS

CIMS

1.
2.
3.
4.
5.
6.
7.
CIMS

Waiting

Excessive Motion

Transportation

Processing
Processing
Defect

Inventory

CIMS

CIMS

1)
2)
3)
4)
5)

(1)
(2)
(3)

CIMS

(
)

CIMS

CIMS

CIMS

CIMS

CIMS

(
)

CIMS

CIMS

CIMS

//

//

CIMS

CIMS

CIMS

JIT

LCIA

SMED

LAYOUT

IE
5S

CIMS

CIMS

(ISO/QS9000)

PFEP

CIMS

CIMS

CIMS

CIMS

Synchronizing Processes

CIMS

Total Product Cycle Time-TP/ct

TP/ct

CIMS

CIMS

CIMS

CIMS

CIMS

PFP
PFP

CIMS

2.
1.

(
)

3.
5.

CIMS

4.

CIMS

QS 9000 / ISO 9000

/
PPAP

D/PFMEA

APQP

CIMS

//SPC

/
DOE
/
/

QS9000

Quality Planning
Quality Controluality Improvement

CIMS

CIMS

CIMS

, ,

CIMS

0.2

1.6

2.9

2.0

/100

60.0

65.0

82.3

97.0

/.

5.7

9.1

7.8

7.8

4.1

4.9

12.9

14.4

/1

16.8

21.2

25.1

36.2

69.3

71.3

17.3

0.6

119

8.7

67.1

14.8

380.3

370.0

46.4

173.3

61.6

1.4

0.4

0.4

5.0

4.8

11.7

12.1

04

3.0

2.7

0.9

1.9

CIMS

:
207090
21

CIMS

CIMS

CIMS

CIMS

CIMS

, ,

CIMS

Pull Systems
Definition

A method of controlling the flow of resources

by replacing what has been consumed

Supplier Process

Supermarket

Customer Process

Make What the Customer Needs

When it is Needed
In the Quantity Needed

CIMS

CIMS

CIMS

KANBAN

...
..

..

CIMS

PART NO.

PART NO.

CIMS

NO.

1
2 POST

3
4
5
6

7
8

CIMS

A)
B)
C)
D)
E)

CIMS

YES

CIMS

NO

CIMS

CIMS

3 4

CIMS

Mon
Build
Order

Part
A
Part
B
Part
C
Part
D
Part
E

CIMS

Tues

Wed Thurs

Fri

Sat

Sun

Build Order
Sequenced and Timed

8:40

8:50

9:00

9:10

9:20

Card (Part A)
Card (Part B)

Card (Part C)

One column per pitch

(Equals 10 minutes)

Card (Part B)

Card (Part B)

Std Pack = 10pcs

Takt Time = 1 min.

8:30

Card (Part C)

Part
C

Card (Part B)

Part
B

CIMS

8:20

Card (Part A)

Part
A

8:10

Card (Part A)

One row per

part number

8:00

Kanban
(pull card)

1962

1970
60
1982
98

1980
87/4.2
CIMS

CIMS

5S
CIMS

5S
SEIRI

SET

SEITON

SORT

SEISO

SWEEP

SEIKETSU

SHINE

SHITSUKE

STRICT

CIMS

5S
SEIRI

SET

SEITON

SORT

SEISO

SWEEP

SEIKETSU
SHITSUKE
CIMS

STANDARDIZED
SELFDISCIPLINE

5S
CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

3s,

CIMS

CIMS

5s
CIMS

CIMS

5S

CIMS

CIMS

3
1
2
3

CIMS

CIMS

CIMS

CIMS

CIMS

XX

CIMS

XX

CIMS

CIMS

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

2270

28

29

30

31

CIMS

CIMS

CIMS

AC 53

STORE

STORE

Part #__________________________
Description_____________________
Std. Pack_______________________
Min____________ Max____________
Store Loc_______ Use Loc________
Supplier________________________
Delivery Date - M - T - W - T - F - S
Time___________________________

CIMS

Part #__________________________
Description_____________________
Std. Pack_______________________
Min____________ Max____________
Store Loc_______ Use Loc________
Supplier________________________
Delivery Date - M - T - W - T - F - S
Time___________________________

STORE
Part #__________________________
Description_____________________
Std. Pack_______________________
Min____________ Max____________
Store Loc_______ Use Loc________
Supplier________________________
Delivery Date - M - T - W - T - F - S
Time___________________________

CIMS

N
W

CIMS

S
:

10X10

CIMS

--

CIMS

CIMS

CIMS

CIMS

CIMS

CIMS

Consider Key Questions

Where can you use continuous flow processing?
(Batch Process vs. Continuous Flow)

Batch Process
Process
A

Process
B

Process
C

Continuous Flow (One-Piece Flow)

Process
A

Process Process
B
C
Elapsed Time:
01 Minute

CIMS

Elapsed Time:
60 Minutes

Batch Process
Process
A

Process
B

Process
C
Elapsed Time:
60 Minutes

Continuous Flow (One-Piece Flow)

Process Process Process
A
B
C
Elapsed Time:
01 Minute

CIMS

Takt Time 1

Takt Time

3T/T
CIMS

Work-

Workload

load

Time
CIMS

Time

ABCD

A1000
B2000
C10000
D15000
20
?

CIMS

Daily Production

Daily Production
Mon 4370 Part D
Part D

Tue 4370 Part D

Thu 4370 Part C

Fri

Part B 655
Part D
Part A
Part B
Part C

Wed 4370 Part D

Part D

Part A 218

Part A
Part B
Part C

Part C 874
Part D
Part A
Part B
Part C

3277 B 1092 A

Part D 2622
Part D
Part A
Part B
Part C

Part D

Part D
Part A
Part B
Part C

Part C

Part D

Part A & B

Mon.

Tue.

Wed.

CIMS

Thu .

Fri.

Mon.

Tue.

Wed.

Thu .

Fri.

Just in time

22

1,100

50

9.2/

550

25

18.4/

110

/
1760

/
80

CIMS

92/
5.8/

AABAABAA
BAABAABC

CIMS

F1

F17
1.2.43.
4.

CIMS

Step 1 -
Example:
H 2O

GAS

SET - EXTERNAL ( 0 SEC.)

7,

14

CIMS

Step 1 -
Example:

H2O

GAS

GO - INTERNAL ( 10 SEC.)
6
14. 1.

.
.

CIMS

Step 1 -
Example:

GAS

H 2O

READY - EXTERNAL ( 14 SEC.)

CIMS

AB

CIMS

Step 1

AB

CIMS

Step 2

CIMS

Step 3

Quick tool attachments: One motion & one turn methods

SPRING STOP

Clamp
Spring-loaded
check pin stops
inside diameter
of tooling
U-SLOT COLLAR

U-slot
collar
Stop
to
prevent
collar from
rotating

CIMS

CAM

Plate

Attach

Fasten

PEAR-SHAPED
TOOLING

Workpiece
Release

C-WASHER/
Insert &
U-WASHER
remove
C-washer without completely
removing nut.
Nut C-washer

Attach &
Remove
SLOTTED NUT-BOLT
/SPLIT THREAD

Threads
removed
Threads
removed

Step 3

Spacer for adjusting to

the standard die height

Male Die
Male Die

X
Female Die

Dimension X = Standard Die Height

CIMS

Female Die

Step 3

Bolt
Nut

Die A
A: A spacer is welded

Die B
B: Unchanged

Die C
C: Machined

Dimension X = Standard Height

CIMS

Step 3

clamping site
standardization

Die B

Die A

X
80

30

50

80

30

clamping site
standardization

standardization jig
at clamping site

50

shim for standardizing

die height

Dimension X = Standard Height

CIMS

Step 3

Production over

Replacement die

Die Transfer
Cart
Safety Latch

CIMS

Safety Stops

Step 3

Production Over

Replacement die

Replacement die

Production Over

Top View
Ball Transfers

Front View

CIMS

Step 3
Acme
Hoist

Acme
Hoist

Production Over

Replacement Die

CIMS

Step 4

CIMS

Step 5

Why?

Average Time per Changeover

June 1999

70
60
50

40
Minutes
GOAL = 10 MIN.

30
20
10
0
1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Day of Month
Date
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Changeovers 2 3 1 2 4 2 3 1 2 4 2 3 1 2 4 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2
Time
98 195 55 106 200 130 180 58 110 200 102 150 45 140 260 180 58 114 186 60 98 135 44 84 117 45 80 105 31 60
Ave Time
49 65 55 53 50 65 60 58 55 50 51 50 45 70 65 60 58 57 62 60 49 45 44 42 39 45 40 35 31 30

CIMS

CIMS

()

CIMS

CIMS

STOP

100

CIMS

Errors

Can be
made by:
1. a person
2. a machine
3. a process

1.
2.
3.
4.
5.

6.
CIMS

CIMS

HeavenTech

ANDON

STOP

CIMS

CIMS

CIMS

MUDA

T.T()

CIMS

T.T

T.T

T.T

T.T=

C.T
C.T

CIMS

T/T

Takt Time

T.T

T.T

Cycle Time

CIMS

C/T

CIMS

Step1
Step2

Step3

Step4

CIMS

(2-3)

C.T

CIMS

=
CIMS

1460

/+ /

CIMS

T.T

CIMS

CIMS

CIMS

CIMS

CIMS

TT

TT

TT

A B C D

A B C D

C.T

CIMS

A B C D

CIMS

CIMS

T,T

T,T

C D

A B

CIMS

CIMS

T akt
Time

55"

76 "

1.38

55 "

78 "

1.41

2.79

CIMS

CDCD

T.T

350

78 "

48 "

0.61

143

193 "

52 "

0.27

0.88

CIMS

1000

2.79

493

0.88

800

2.46

2293

TT

6.13

6.13

1000

2.79

493

0.88

800

2.46

2293

6.13

0.13

CIMS

BOX

C/T

T/T

T/T

CIMS

T/T

POST
ANDON

CIMS

I T

CIMS

CIMS

CIMS

pallet

CIMS

(SNP)

CIMS

CIMS

SNP

0.5
0.2
0.6
0.2
5/

1
8

=0.1

=0.5

=0.1

CIMS

A 100/

B 150/
C 150/

CIMS

3
3

CIMS

a
c

CIMS

N=a+b+c
M
=M-N (M>N)
=N-M M<N)

CIMS

~~

CIMS

CIMS

CIMS

1
1

2
2

()

()

()

()

CIMS

SNP

=0.5

=0.5

=0.2

=0.1

CIMS

=0.5

=0.1

CIMS

A30
428

25

30

120

16

17

30

20

30 A16120

1650

CIMS

CIMS

CIMS

l
l

l 5S

l DFM/DFADesign for
Manufacturing/Design
for Assembly
CIMS

l /

l
UU

CIMS

l Group Technology

l value stream mapping

l U

CIMS

1.

2. U11
3.

4.
5.

6.
7.
CIMS