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Lean Metrics
i & Future State
S
VSM
S
Session 15
PEMP EMM515
Session Objectives
Fundamentals of Lean Metrics.
Premiere Manufacturing Case Study
Premiere
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Baseline
17,040 units
170 seconds
34 days
On time delivery
88 percent
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Uptime
84 percent
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L
Lean
Metrics:
M t i The
Th Fundamentals
F d
t l
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Obstacle
Solution
Buffer inventory
Safety inventory
I bilit to
Inability
t sustain
t i a continuous
ti
flow
fl
from the
Most downstream operation to the
customer
Finished-good
Fi
ih d
d
supermarket
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Based on its discussions with operators, the team believes it can achieve
the new target by making the following changes:
Improving programming and tooling maintenance to eliminate the need for
deburringg one operator
p
required.
q
Distributing the work of the three remaining operations between two operators.
Reducing change over time in machining to 15min.
Achievingg changeover
g
time of less than one minute in
crimping/testing/marking.
The team decides that the value stream should operate with three
operators. Although
Al h
h the
h personnell requirement
i
was calculated
l l d as 2.7
2
operators at a total cycle time of 150 seconds, there is simply too much
p
The operator
p
balance chart for the future state is
for jjust two operators.
shown in Fig 6-2.
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Kanbans
The team decides that the value stream requires the following types of
kanbans in the following locations:
1. Withdrawal kanbans that will tell the runner how many units should be
pulled from the finished-goods supermarket and staged in shipping.
2. Production kanbans that tell operators in the crimping/testing/marking
cell how many units must be produced to replenish those pulled from the
finished goods supermarket.
finished-goods
supermarket
3. Signal kanbans at the in-process supermarket between machining and the
p g
g
g cell that tell the machiningg operator
p
how manyy
crimping/testing/marking
units have been pulled from the supermarket.
4. Signal kanbans just upstream of machining that tell the supplier how
many units
i have
h
been
b
pulled
ll d from
f
raw material
i l inventory.
i
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Runnerss route
Runner
route, step 2
1. Team draws a dashed arrow from finished goods supermarket
icon to the shipping
pp g icon to represent
p
the next legg of the
runners route.
2. Just beneath the dashed arrow, the team draws a supermarket
parts icon and a physical material pull icon to show that the
runner pulls parts from the supermarket to the stage of
shipment.
shipment
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You may wonder where the runner gets the production kanbans.
Production kanbans are attached to containers of finished goods. When a
runner pulls a container of finished goods from a supermarket to stage
for shipment, he or she also pulls the production kanban from the
container. The production kanban is then used to initiate replenishment
of the inventory that has just been pulled.
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