Вы находитесь на странице: 1из 52

Technology

Forge

Version
1.0

Arena Tutorial 10

Lean Models
Part 1
Copyright 2010
All rights reserved
Mark Polczynski
mhp.techforge@gmail.com

Arena Tutorial 10 - Lean Models - Part 1

Before we start, please note that:

Lean is not a bag of tricks to be capriciously applied in a


piecemeal manner to instantly achieve world-class
performance.

Lean is a way of thinking about system that can benefit


from judicious and well-planned application of
appropriate techniques that support the lean paradigm.

This tutorial is about modeling a set of lean techniques


commonly applied in lean systems.
You need to apply the techniques covered in this
tutorial in the true spirit of lean thinking.

Arena Tutorial 10 - Lean Models - Part 1

Why build Arena models of lean techniques?


Predict potential benefits of changing to lean production,
Evaluate actual results of lean system vs. predicted benefit.
Work out details of particular lean implementation before
making changes.

Arena Tutorial 10 - Lean Models - Part 1

Arena models for this tutorial:


1. Batch processing
2. Single piece continuous flow with customer pull
- With single piece buffer
3. FIFO Lanes
- For multiple part types
4. Supermarket Pull
- Restock on Order Point
5. Load Leveling Box
6. Kanban production

This
tutorial

- Two-bin kanban system

Arena Tutorial 10 - Lean Models - Part 1

Batch
processing at
its worst

Each operation
receives
production order
from Production
Control

Operation pulls
parts from
stockroom

Operation sends
parts to
stockroom

Arena Tutorial 10 - Lean Models - Part 1

Arena model
for batch
processing

Production Control
sends a Production
Order for a batch of
Type 2 parts

Operation 1 works
on a batch of
Type 1 parts

Operation 2
converts Type 1
parts into
Type 2 parts

All parts are stored in


the stock room
between operations
Arena Tutorial 10 - Lean Models - Part 1

Operation 1
creates Type 1
parts

Arena Tutorial 10 - Lean Models - Part 1

Queue
1

Operation 1
sends Type 1
parts to the
Stock Room
Arena Tutorial 10 - Lean Models - Part 1

Production
Order 2 stored
in Queue 1 of
the Match
module

Parts stored in stock


room until Production
Order is received
Arena Tutorial 10 - Lean Models - Part 1

batch of
parts allowed
to move to
queue 2

Production
Order 2 arrives
in queue 1

Parts stored in stock


room until Production
Order is received
Arena Tutorial 10 - Lean Models - Part 1

10

Queue 2
for lower
input

Production
Order 2

Queue 1
for upper
input

How the Match


module works
Arena Tutorial 10 - Lean Models - Part 1

11

Arena Tutorial 10 - Lean Models - Part 1

Operation 2
works on
individual parts12

Send Type 2
parts to the
Stock Room
Arena Tutorial 10 - Lean Models - Part 1

13

Simulation just
after start of
run

Production order
for Type 2 parts
has arrived

Operation 1 is
filling batch of 10
Type 1 parts
Arena Tutorial 10 - Lean Models - Part 1

14

Operation 1 is
working on
parts

7 parts in
Operation 2
queue
Operation 2 has
completed 2 of the
batch of 10 parts

Operation 2 is
working on one
part
Arena Tutorial 10 - Lean Models - Part 1

15

Operation 2
complete and batch
of 10 Type 2 part
sent to Stock Room

Completed
batch of Type
2 parts
Arena Tutorial 10 - Lean Models - Part 1

16

Arena models for this tutorial:


1. Batch processing
2. Single piece continuous flow with customer
pull
- With single piece buffer
3. FIFO Lanes
- For multiple part types
4. Supermarket
- Restock on Order Point
5. Load Leveling Box
6. Kanban production
- Two-bin kanban system

Arena Tutorial 10 - Lean Models - Part 1

17

Ideal lean system:


Single piece continuous flow with customer pull
Hey comrade!
I need
another part
down here!

Im working as
fast as I can,
you capitalist
lackey!

Arena Tutorial 10 - Lean Models - Part 1

18

Single piece
continuous flow
with customer
pull

Big Brother to
Rasputin:
Uncle Joe wants a
couple of pizzas
Production
Control

Operation 1

Operation 2

Customer

Hey Leo, lets have


a thin crust down
here ASAP!
Arena Tutorial 10 - Lean Models - Part 1

19

Ready
yet?

Ready
yet?

Ready
yet?

Chill out!
Im almost
done!

Single piece
continuous flow
with customer
pull

Upstream operator pushes


their part downstream when
downstream operator is done
working on their part.

Arena Tutorial 10 - Lean Models - Part 1

20

Arena model for


single piece
continuous flow
with customer
pull.
Operation 1 sends
parts to Operation 2
when Operation 2 is
ready to work on
them.

Production
Control sends
production
order to
Operation 2

Arena Tutorial 10 - Lean Models - Part 1

21

Generating the
Production
Order

Hold order until


Operation 2 is
ready

Arena Tutorial 10 - Lean Models - Part 1

22

Production
Order
Use duplicate to
generate part
entity

Initiate
work on
parts
Arena Tutorial 10 - Lean Models - Part 1

23

Operation 2
process is same,
except use
Operator 2
resource.

Convert
duplicate
Production
Order into Part
entity

Operation 1
works on
parts
Arena Tutorial 10 - Lean Models - Part 1

24

Where the
Parts come
from

Original Part
moves to
Operation 2
Duplicate Part recirculates to become next
Part worked on

Arena Tutorial 10 - Lean Models - Part 1

25

Resource utilization
for single piece
continuous flow with
customer pull

Operation 1
starts
immediately

Gaps due to
variation in
operation delay
times

Note: Production is
balanced - same
average delay for
both operations

Operation 2
starts when
Operation 1
finishes the first
part
Arena Tutorial 10 - Lean Models - Part 1

26

Add one-piece buffer


between operations

Put in onepiece buffer


between each
operation.

One-piece buffer:
Allow upstream operator to push (1) piece into space between operations.

Arena Tutorial 10 - Lean Models - Part 1

27

Occasionally
see 1 piece in
queue

Add one-piece buffer


between operations
Arena Tutorial 10 - Lean Models - Part 1

28

Add one-piece buffer


between operations

Note: Production is
balanced - same
average delay for
both operations

Gaps disappear
for both
operators

Arena Tutorial 10 - Lean Models - Part 1

29

Operation 1
spends half its
time waiting
for Operation 2

Effect of doubling
process delay time for
Operation 2

Operation
2 always
busy

Arena Tutorial 10 - Lean Models - Part 1

30

Arena models for this tutorial:


1. Batch processing
2. Single piece continuous flow with customer pull
- With single piece buffer
3. FIFO Lanes
- For multiple part types
4. Supermarket
- Restock on Order Point
5. Load Leveling Box
6. Kanban production
- Two-bin kanban system

Arena Tutorial 10 - Lean Models - Part 1

31

In

FIFO Lane
A FIFO lane can be placed between unbalanced
operations to smooth out flow.
This is a type of buffer where the first piece
put in the buffer is the first piece pulled out.
The opposite type of buffer is LIFO
last in-first-out.

Ou
t

Here are two other situations that can


benefit from a FIFO lane:
If the parts are perishable or
have a short shelf-life,
If the parts are customized.
Arena Tutorial 10 - Lean Models - Part 1

32

Spee
d it
up!

Full

Im going
as fast as I
can

FIFO lane
(5 slots)
Thats
better!

Empt
y
slot

Arena Tutorial 10 - Lean Models - Part 1

Thanks

33

Heres how we draw a


FIFO lane

If FIFO lane is
full, then stop
working on
parts

Arena Tutorial 10 - Lean Models - Part 1

34

Arena model
with FIFO
lane

Fast
operatio
n

FIOFO Lane
(5 slots)
Arena Tutorial 10 - Lean Models - Part 1

Slow
operatio
n
35

Kanban
card

Production Control
sends kanban card
to Operation 2 to
initiate production
Arena Tutorial 10 - Lean Models - Part 1

36

Previous example:
Operators could
monitor
upstream/downstrea
m operations

This example:
Operation 2 notifies
Operation 1 that it is
ready using a kanban
card

Arena Tutorial 10 - Lean Models - Part 1

37

Production control
initiates a
production order
with a single
kanban card

One kanban
card initiates
production

Arena Tutorial 10 - Lean Models - Part 1

38

Operation 2
specifies FIFO
quantity and holds
kanban card until
there is no WIP in
Operation 2.

Arena Tutorial 10 - Lean Models - Part 1

39

Create a Part
entity and
dispose of the
Kanban Card
entity
Kanba
n card

Part

Arena Tutorial 10 - Lean Models - Part 1

40

Operation 1
runs about
twice as fast as
Operation 2

Arena Tutorial 10 - Lean Models - Part 1

41

Origin
al Part

Original Part entity


moves into FIFO
lane.

Arena Tutorial 10 - Lean Models - Part 1

42

Duplicate Part entity


creates more parts at
Operation 1

Duplicate Part
recirculation
path
Arena Tutorial 10 - Lean Models - Part 1

43

Arena model
with FIFO
lane
Operation 1
idle half the
time

Never
more than
5 parts

Arena Tutorial 10 - Lean Models - Part 1

44

Operation 1
supplies
Operations 2 and
3 using FIFO
Im going
lanes.
as fast as I
can

Spee
d it
up!

Generi
c Part
entitie
s

More
parts
!!
Arena Tutorial 10 - Lean Models - Part 1

45

Copy
and
Paste

Create kanban
cards for part
types A and B

Arena Tutorial 10 - Lean Models - Part 1

46

Send kanban
card to
Operation 1

Modify Operation 2 and


Operation 3 modules as
needed
Arena Tutorial 10 - Lean Models - Part 1

47

Route kanban
cards and assign
part types

Arena Tutorial 10 - Lean Models - Part 1

48

To FIFO
lane

Route part to
appropriate FIFO
lane
Arena Tutorial 10 - Lean Models - Part 1

49

Arena model
with (2) FIFO
lanes
Never
more than
5 parts

Arena Tutorial 10 - Lean Models - Part 1

50

Arena models for this tutorial:


1. Batch processing
2. Single piece continuous flow with customer pull
- With single piece buffer
3. FIFO Lanes
- For multiple part types

Next
tutorial

4. Supermarket Pull
- Restock on Order Point
5. Load Leveling Box
6. Kanban production
- Two-bin kanban system

Arena Tutorial 10 - Lean Models - Part 1

51

Contact the Author:


Mark Polczynski, PhD
The Technology Forge
mhp.techforge@gmail
.com

Arena Tutorial 10 - Lean Models - Part 1

52

Вам также может понравиться