Working with Machines-The Nuts and Bolts of Lean Operations with Jidoka PDF
Preview Working with Machines-The Nuts and Bolts of Lean Operations with Jidoka
Working with M achines The Nuts and Bolts of Lean Operations with Jidoka by Michel Baudin Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business A PRODUCTIVITY PRESS BOOK First published 2007 by Productivity Press Published 2018 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2007 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an lnforma business No claim to original U.S. Government works ISBN-13: 978-1-56327-329-2 (hbk) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. 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CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Library of Congress Cataloguing-in-Publication Data Baudin, Michel. Working with machines : the nuts and bolts of lean operations with jidoka / by Michel Baudin. p.cm. ISBN-13: 978-1-56327-329-2 (alk. paper) I. Manufacturing processes. 2. Production planning. 3. Machinery in the workplace. I. Title. TS183.B4325 2007 658.5--dc22 2007006607 ii Working with Machines Acknowledgements This book is the distillation of many projects, and I would like to acknowl edge the contributions... Kei Abe, Kevin Hop Jim Ayers, Crispin Vincenti-Brown Dale Bayley, Tom Berghan Hormoz Moghare Pierre Choussat Christian Thomas Bob Shroer Charles Parks Hormoz Mogharei Shahrukh Irani Shunji Yagyu Jose Ignacio Erausquin Asaf Degani Working with Machines iii Contents Introduction.........................................................................................................1 Jidoka = Working with Machines............................................... 1 Working with machines and competitiveness...................................................3 Inside the book................................................................................................5 PART I Human—Machine interfaces.............................................9 CHAPTER 1 Using machine controls...........................................................11 Performing steps on machines.......................................................................12 Unloading and loading...................................................................................12 Pressing the right button................................................................................14 Monitoring and exception handling...............................................................17 Usability engineering principles......................................................................21 CHAPTER 2 Performing operations on machines.......................................35 Performing operations...................................................................................36 Sequencing constraints..................................................................................37 Natural mappings..........................................................................................38 From process-centered to result-centered interfaces......................................40 Working with Machines v CHAPTER 3 Understanding the process.....................................................51 Machines used at work versus everyday life...................................................52 Categories of machine processes...................................................................53 How much do the operators need to know?.................................................54 The example of sputtering.............................................................................56 How operators learn......................................................................................59 CHAPTER 4 Programming machines..........................................................63 Impact of machine programmability..............................................................64 Common features of programmable controllers............................................64 Impact of programmability on shop floor....................................................71 Characteristics of machine programs.............................................................76 Who should program machines?............................................ 79 Process programs as tangible assets...............................................................81 PA RT II Machine cells.........................................................................85 CHAPTER 5 Cellular manufacturing with machines.....................................87 Lean manufacturing cells with machines........................................................88 Examples of machine cells............................................................................88 Defining a lean manufacturing cell.................................................................95 Issues with machine cells...............................................................................96 Alternative meanings of the word “cell”......................................................103 The value of cells.........................................................................................104 CHAPTER 6 Design and implementation of a machine cell.......................107 About cell design and implementation.........................................................108 Project planning and project phases.............................................................108 Analysis and design......................................................................................114 Equipment installation.................................................................................124 Cell startup and finishing.............................................................................127 CHAPTER 7 From operator job design to task assignment........................133 Operator job design.....................................................................................134 Related charts...............................................................................................142 Daily task assignments.................................................................................148 vi Working with Machines CHAPTER 8 Cell automation and chaku-chaku line.....................................155 What is a chaku-chaku line?...........................................................................156 Detailed features of chaku-chaku lines...........................................................158 Multiple cells in one big room......................................................................167 Operators in chaku-chaku lines......................................................................169 Chaku-chaku line implementation..................................................................170 CHAPTER 9 Grouping cells into focused factories...................................173 Cells versus focused factories.......................................................................174 A failed cellularization example....................................................................174 The better way.............................................................................................177 A general approach......................................................................................180 PART III Common services and monuments................................185 CHAPTER 10 Working with monuments....................................................187 What is a monument?..................................................................................188 What is wrong with monuments?.................................................................191 What to do about monuments.....................................................................192 Examples of monuments.............................................................................200 CHAPTER 11 Setup time reduction............................................................215 Setup time reduction, monuments, and flexible lines...................................216 Setup times for individual machines versus lines.........................................216 SMED.........................................................................................................220 Setup time reduction management...............................................................222 Outline of a setup time reduction project....................................................225 Changeover time analysis of a machine........................................................227 General principles for external setup tasks..................................................237 General principles for externalizing internal setup tasks..............................238 General principles for improving internal setup tasks...................................239 PART IV Automation.......................................................................243 CHAPTER 12 The lean approach to automation.........................................245 Is lean manufacturing anti-automation?........................................................246 Jidoka, autonomation, and automation.........................................................246 Working with Machines vii The seven steps of automation for machining.............................................250 Underlying principles...................................................................................253 CHAPTER 13 Improving legacy automated systems...................................257 What are legacy systems?.............................................................................258 Legacy automated systems in machining......................................................258 Increasing availability...................................................................................261 Routine operations.......................................................................................263 Starting the machine....................................................................................268 Periodic actions...........................................................................................268 PA RT V Machine maintenance.........................................................271 CHAPTER 14 Machine and facilities maintenance......................................273 About maintenance......................................................................................274 The economics of maintenance...................................................................275 Participants in the maintenance business.....................................................277 Balance between planned and unplanned activities.......................................281 Preventive maintenance productivity...........................................................283 Failures and microstoppages................................................................ 284 CHAPTER 15 Improving maintenance................................................. 287 Strategies for maintenance improvement.....................................................288 Reliability-centered maintenance (RCM)......................................................288 Total productive maintenance (TPM)...........................................................292 Maintenance organization............................................................................304 CHAPTER 16 Maintenance information systems........................................309 Computer systems for maintenance.............................................................310 Diagnosis and failure analysis.......................................................................314 Administration, documentation, and paperwork..........................................317 CHAPTER 17 Overall Equipment Effectiveness (OEE).............................323 Is faster better?............................................................................................324 OEE as a machine performance indicator....................................................325 OEE calculations.........................................................................................328 OEE analysis and machine performance improvement................................331 viii Working with Machines Appropriate and inappropriate use of OEE to improve machine performance................................................................................................337 Where to go from here?..................................................................................339 Bibliography....................................................................................................343 Books about machining................................................................................343 Books on usability engineering.....................................................................344 Industrial engineering..................................................................................345 Operator job design in cells.........................................................................345 Chaku-chaku lines.........................................................................................345 Focused factories.........................................................................................345 Setup time reduction............................................. 346 Automation..................................................................................................346 Maintenance................................................................................................347 Index..............................................................................................................349 Working with Machines ix
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