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TQM UPC
- 1. Standard Work-Manufacturing 弌舒仆亟舒仆仂亠 仗仂亳亰于仂亟于仂 舒弍仂 Arkhipov Pavel flw. United Technologies Corp. (UTC) Achieving Competitive Excellence (ACE) Management Work Flow to Improve Product Quality and Response Time 丕仗舒于仍亠仆亳亠 亠仆仂仍仂亞亳亠从亳仄 仗仂亠仂仄 亟仍 仍亠仆亳 从舒亠于舒 仗仂亟从仂于 亳 仆亳亢亠仆亳 于亠仄亠仆亳 亠舒亞亳仂于舒仆亳 仆舒 亰舒仗仂 亰舒从舒亰亳从仂于
- 2. Arkhipov PA, flw UTS-ACE The Seven Wastes 弌亠仄 于亳亟仂于 仗仂亠 1. Product defects/ 亠亠从 仗仂亟从亳亳 2. Over production/亰仍亳从亳 仗仂亟从亳亳 3. Transportation/ 丐舒仆仗仂亳仂于从舒 4. Processing/ 舒弍仂从舒 亟仂从仄亠仆舒亳亳 5. Inventory/ 丐 6. Unnecessary movement/ 亠 仆亢仆亠 仗亠亠仄亠亠仆亳 7. Waiting/ 亢亳亟舒仆亳
- 3. Arkhipov PA, flw UTS-ACE Cost of Poor Quality Elements(The Iceberg Model) 亅仍亠仄亠仆 亳亰亟亠亢亠从 亳亰-亰舒 仗仍仂仂亞仂 从舒亠于舒 (亶弍亠亞) Extra Inspection (仂仗仂仍仆亳亠仍仆舒 仗仂于亠从舒) Warranty (舒舒仆亳) Escapes (丕亠从舒) Scrap (仂亟) Rework (亠亠亟亠仍从舒) Engineering Changes (仆亢亠仆亠仆亠 亳亰仄亠仆亠仆亳) Long Cycle Times (丕亟仍亳仆亠仆亳亠 亳从仍舒) Extra Setups (仂仗仂仍仆亳亠仍仆亠 舒仆仂于从亳) Expediting Costs (丕从仂亠仆亳亠 亳亰亟亠亢亠从) Lost Sales (仂亠礌仆亠 仗仂亟舒亢亳) Late Delivery Charges (仂亰亟仆亳亠 舒仂亟 仆舒 亟仂舒于从) Lost Customer Loyalty (仂亠 仍仂磿仆仂亳 从仍亳亠仆仂于) Excess Inventory (亰仍亳仆亠亠 亳亰仂弍亠舒亠仍于仂) Non - Visible 5-8 % of Sales 亠于亳亟亳仄亠 5-8% 仗仂亟舒亢 Visible 2-3 % of Sales 亳亟亳仄亠 2-3% 仗仂亟舒亢 Repair (亠仄仂仆) Recurring Service Bulletins (仂于仂 亠于亳仆 弍ﾐ姉姉却.) Recurring Engineering Notices (仂于仂亠仆亳亠 亳仆亢亠仆亠仆亶 亰舒仄亠舒仆亳亶 Non-Contractual Warranty (仆亠-从仂仆舒从仆舒 亞舒舒仆亳) Supplier Quality (舒亠于仂 仗仂舒于亳从仂于) Lost Credibility (仂亠 亟仂于亠亳) Hidden ? 弌从亠
- 4. Arkhipov PA, flw UTS-ACE Standard Work 弌舒仆亟舒仆舒 舒弍仂舒 A set of tools to:/ 舒弍仂 仄亠仂亟仂于 亟仍 仂亞仂, 仂弍: Establish a routine for work to be performed/ 丕舒仆仂于亳 仂弍仆亶 仗仂磲仂从 亟仍 于仗仂仍仆磳仄仂亶 舒弍仂 Make scheduling easier/ 丕仗仂亳 亞舒亳从 仗仍舒仆亳仂于舒仆亳 Establish a relationship between person and machine/ 丕舒仆仂于亳 于亰舒亳仄仂于磶 仄亠亢亟 亠仍仂于亠从仂仄 亳 仂弍仂亟仂于舒仆亳亠仄 Serve as a basis for improvement, making problems obvious 仗仂仍亰仂于舒 亠 从舒从 弍舒亰仂于 亟仍 仍亠仆亳亶, 亟仍 仂亞仂 仂 弍 亟亠仍舒 仗仂弍仍亠仄 仂亠于亳亟仆仂亶 Prohibit backsliding/ 舒仗亠亳 仂仗仍亠仆亳 仂 仆仂仄 Help eliminate waste/弌仗仂仂弍于仂于舒 舒仆亠仆亳 仗仂亠 Definition 仗亠亟亠仍亠仆亳亠
- 5. Arkhipov PA, flw UTS-ACE Three Principles of Standard Work 丐亳 仗亳仆亳仗舒 弌舒仆亟舒仆仂亶 舒弍仂 Standard Work will define the interaction of person, machine, and material by applying three basic principles: /弌舒仆亟舒仆舒 舒弍仂舒 仂仗亠亟亠仍磳 于亰舒亳仄仂亟亠亶于亳亠 于 仗仂亳亰于仂亟于亠仆仆仂仄 仗仂亠亠 仍ﾐ莞黍, 仄舒亳仆 亳 仄舒亠亳舒仍仂于, 仗亳仄亠仆 亳 仂仆仂于仆 仗亳仆亳仗舒: Takt /丐舒从 Flow (work sequence) / 仂仂从 (仗仂仍亠亟仂于舒亠仍仆仂 舒弍仂) Pull (standard work-in-process)/ Pull (仗仂亠 弌舒仆亟舒仆仂亶 舒弍仂)
- 6. Arkhipov PA, flw UTS-ACE Three Principles of Standard Work 丐亳 仗亳仆亳仗舒 弌舒仆亟舒仆仂亶 舒弍仂 Takt time 丐舒从 Standard Work 弌舒仆亟舒仆舒 舒弍仂舒 Begin 舒舒仍仂 Finish 舒于亠亠仆亳亠 12 3 4 5 * No Return Trip = No Waste 亠 于仂亰于舒舒 =亠 仗仂亠 (standard work-in-process) 弌舒仆亟舒仆亶 仗仂亠 舒弍仂 Pull (work sequence) 仗仂仍亠亟仂于舒亠仍仆仂 舒弍仂 Flow 仂仂从 仂亟仂仍亢亠仆亳亠
- 7. Arkhipov PA, flw UTS-ACE Takt Time 亠仄 丐舒从舒 Takt time is your customer requirement. The beat at which each product must be produced to meet your schedule requirement. / 亠仄 丐舒从舒 仂仗亠亟亠仍磳 亠弍仂于舒仆亳礆亳 舒从舒亰亳从舒. 亅仂 亳仄, 于 从仂仂仂仄 亟仂仍亢亠仆 仗仂亳亰于仂亟亳 从舒亢亟亶 仗仂亟从, 仂弍 仂仂于亠于仂于舒 亠弍仂于舒仆亳礆 亞舒亳从舒 Takt Time = Total daily working time Total daily customer demand Definition 仗亠亟亠仍亠仆亳亠 亠仄 丐舒从舒 = 弍亠亠 亠亢亠亟仆亠于仆仂亠 舒弍仂亠亠 于亠仄 弍亳亶 亠亢亠亟仆亠于仆亶 仗仂亠弍亳亠仍从亳亶 仗仂
- 8. Arkhipov PA, flw UTS-ACE Example 亳仄亠 Lost Available Time 亠仄 仆舒 仗仂亠亳 Weekly Time (in minutes) 亢亠仆亠亟亠仍仆仂亠 于亠仄 (于 仄亳仆.) Daily Time (in minutes) 亢亠亟仆亠于仆仂亠 于亠仄 (于 仄亳仆.) Weekly New 5S, TPM & QCPC shutdown/ 亢亠仆亠亟亠仍仆亠 弍仂亳 于 舒仄从舒 仆仂于 5 S, TPM 亳 QCPC 120 24 Weekly shutdown meeting 亢亠仆亠亟亠仍仆亠 仂于亠舒仆亳 仗仂 舒仆亠仆亳 弍仂亠于 60 12 Daily cleanup / 亢亠亟仆亠于仆舒 弍仂从舒 75 15 Daily tool box meeting / 亢亠亟仆亠于仆仂亠 仂于亠舒仆亳亠 仗仂 于仂仗仂 亳从舒 亳仆仄亠仆舒仄亳 25 5 Total (仂亞仂 ) 280 Minutes 56 Minutes /
- 9. Arkhipov PA, flw UTS-ACE Manufacturing Available Time 仄亠ﾑ亠亠 于亠仄 Available time for 2 shifts 2 x (480 56) = 848 Minutes 仄亠ﾑ亠亠 于亠仄 仆舒 2 仄亠仆 2丱(480-56)= 848 仄亳仆
- 10. Arkhipov PA, flw UTS-ACE Takt Time 亠仄 丐舒从舒 Takt time = (亠仄 丐舒从) Time available 仄亠ﾑ亠亠 于亠仄 Daily Customer Demand or Daily Flow Rate 亢亠亟仆亠于仆亶 仗仂亠弍亳亠仍从亳亶 仗仂 亳仍亳 亠亢亠亟仆亠于仆亶 从仂亳亳亠仆 仗仂仂从舒 = (848 x 60) seconds per minute (亠从仆亟 于 仄亳仆) 2000 pieces 2 000 亟亠舒仍亠亶 = 25 seconds per piece over 2 shifts 25 亠从仆亟 仆舒 亟亠舒仍 于 2 仄亠仆舒
- 11. Arkhipov PA, flw UTS-ACE Takt Time and Cycle Time 亠仄 丐舒从舒 亳 于亠仄 亳从仍舒 Takt Time = 亠仄 丐舒从舒= Available Time 仄亠ﾑ亠亠 于亠仄 Daily Customer Demand 亢亠亟仆亠于仆亶 仗仂 亰舒从舒亰亳从舒 Cycle Time = Manual + walking + waiting time for one cycle of work sequence 亠仄 亳从仍舒 = 仆舒 仂仗亠舒亳 + 仗亠亠仂亟 + 于亠仄 仂亢亳亟舒仆亳 于 仂亟仆仂仄 亳从仍亠 舒弍仂
- 12. Arkhipov PA, flw UTS-ACE Flow (Work Sequence) 仂仂从 (仗仂仍亠亟仂于舒亠仍仆仂 舒弍仂) The order in which an operator performs manual operations including walking and waiting, and his/her interaction with product flow. 仂磲仂从, 于 从仂仂仂仄 仂仗亠舒仂 于仗仂仍仆磳 仆亠 仂仗亠舒亳亳, 于从仍ﾑ舒 仗亠亠仂亟 亳 仂亢亳亟舒仆亳, 亳 亠亞仂/亠亠 于亰舒亳仄仂亟亠亶于亳亠 仗仂仂从仂仄 仗仂亟从亳亳. 1 2 3 4 5 9 8 7 6 10 1 1 2 1 2 4 3 3 3 Incoming 仂亟亳亠 Outgoing 仂亟亳亠 2 Process Sequence 仂仍亠亟仂于舒亠仍仆仂 仗仂亠舒 Work Sequence 仂仍亠亟仂于舒亠仍仆仂 舒弍仂 Operator A 仗亠舒仂 Operator B 仗亠舒仂 Operator C 仗亠舒仂 弌 Definition 仗亠亟亠仍亠仆亳亠
- 13. Arkhipov PA, flw UTS-ACE Standard Work Tools 弌舒仆亟舒仆亠 亳仆仄亠仆 舒弍仂 Spaghetti Charts Quality Speed Cost
- 14. Arkhipov PA, flw UTS-ACE Standard Work Tools 弌舒仆亟舒仆亠 亳仆仄亠仆 舒弍仂 亳舒亞舒仄仄舒 弌仗舒亞亠亳 舒亠于仂 弌从仂仂 舒舒
- 15. Arkhipov PA, flw UTS-ACE Spaghetti Chart 亳舒亞舒仄仄舒 弌仗舒亞亠亳 Measures the travel distance of the products and the travel distance of the operator in order to highlight unnecessary travel waste./ 亰仄亠亠 舒仂礌亳亠, 从仂仂仂亠 仗仂仂亟 仗仂亟从 亳 舒仂礌亳亠, 从仂仂仂亠 仗仂仂亟亳 仂仗亠舒仂 - 仂 亳 弍亟亠 于亠仍亳亳仆舒 弍亠仗仂仍亠亰仆 仂亢亟亠仆亳亶) BEFORE: 仂 7,992 F/仂于 8 WEEK LEADTIME- 弌仂从 亳亰亞仂仂于仍亠仆亳 PW4000 2nd STAGE HPT VANE PROCESS CENTERS FLOW Part Flow Before Product Cell 于亳亢亠仆亳亠 亟亠舒仍亳 亟仂 仂亰亟舒仆亳 仗仂亳亰于仂亟- 于亠仆仆仂亶 亠亶从亳
- 16. Arkhipov PA, flw UTS-ACE Spaghetti Chart (cont.) 亳舒亞舒仄仄舒 弌仗舒亞亠亳 (仗仂亟仂仍亢亠仆亳亠) AFTER: (仂仍亠) 1,117 FT (1,117 仂于) 3 WEEK LEADTIME 3 仆亠亟亠仍亳 - 仂从 亳亰亞仂仂于仍亠仆亳 PW4000 2nd STAGE HPT VANE BU 253 - VANE CELL 6 Part Flow After Product Cell 仂仂从 亟亠舒仍亳 仗仂仍亠 仂亞舒仆亳亰舒亳亳 仗仂亳亰于仂亟于亠仆 仆仂亶 亠亶从亳
- 17. Arkhipov PA, flw UTS-ACE Time Observation Sheet 亳 从仂仆仂仍 舒弍仂亠亞仂 于亠仄亠仆亳 1. Fill in data on top/ 舒仗仂仍仆亳亠 亟舒仆仆亠 于于亠 弍仍舒仆从舒 2. Observe operator and record tasks/ 舒弍仍ﾐ莞夷膏亠 亰舒 仂仗亠舒仂仂仄 亳 于亠亟亳亠 亰舒仗亳 亰舒亟舒仆亳亶 3. Record elapsed times in the upper squares (start with zero)/ 舒仗亳亳亠 亳亠从亠亠 于亠仄 于 于亠仆亳 从于舒亟舒舒 (仆舒仆亳亠 仆仍) 4. Record task times in lower square/ 舒仗亳亳亠 于亠仄 于仗仂仍仆亠仆亳 亰舒亟舒仆亳 于 仆亳亢仆亠仄 从于舒亟舒亠 5. Make multiple observations/ 亠亟亳亠 从仂仄仗仍亠从仆亠 仆舒弍仍ﾐ莞黍出狐 6. Use second lowest time/ 仗仂仍亰亶亠 于仂仂亠 仆亳亢仆亠亠 于亠仄 7. Note any opportunities for waste reduction/ 舒仗亳亳亠 仍ﾐ英亠 于仂亰仄仂亢仆仂亳 仗仂 仂从舒亠仆亳 仗仂亠 于亠仄亠仆亳 Directions to Complete 仆从亳亳 仗仂 亰舒仗仂仍仆亠仆亳
- 18. Arkhipov PA, flw UTS-ACE Time Observations 仂仆仂仍 亰舒 舒弍仂亳仄 于亠仄亠仆亠仄 Visualizes and records the actual process times to identify waste and facilitate process improvements. (Typically done through video.) 亠仍舒亠 仆舒亞仍磲仆仄 亳 亰舒仗亳于舒亠 舒从亳亠从仂亠 于亠仄 舒弍仂亠亞仂 仗仂亠舒 亟仍 仂亞仂, 仂弍 仗仂亳 仗仂亠 仄仂亟亠仆亳亰舒亳亳 仗仂亳亰于仂亟于舒 (弍仆仂 亟亠仍舒亠 仗仂仄仂 于亳亟亠仂). 0 0 0 0 0 10 12 9 10 10 10 12 9 10 10 29 36 25 29 30 39 48 34 39 40 19 15 18 18 20 58 63 52 57 60 13 12 11 12 12 71 75 63 69 72 16 16 16 18 17 87 91 79 87 89 35 36 32 32 30 122 127 111 119 119 34 30 37 34 34 156 157 148 153 153 10 9 9 9 12 166 166 157 162 165 31 35 31 28 31 Operator 51D280 170 M. Smith Part Number Operation Number Rev. Letter Sum. Letter Part Name Department Number/Name Prepared By Vane Cell 9 S. Cutting PCS/Load Brass Tag Operation Description Machine Description Date Time No. Element Task 1 2 3 4 5 Element Task Time 7 Notes (M-W-A Time) 1 2 3 10 29 18 Drill 5 Holes Unload Part 8 9 Get Part/Walk to Machine Load Part Clamp Part Walk to Get Indicator Indicate Part 4 5 6 Gauge Holes Remove Burrs 12 16 32 34 9 31 Auto-cycle, Operator waits TIME OBSERVATION WORKSHEET 197 201 188 190 196 Total 191 Use the back of this page to sketch workplace
- 19. Arkhipov PA, flw UTS-ACE Time Observation Sheet (cont.) 亳 从仂仆仂仍 舒弍仂亠亞仂 于亠仄亠仆亳 (仗仂亟仂仍亢.) Part Name Department Number/Name Prepared By PCS/Load Operation Description Date Brass Tag Machine Description Time 3 4 5 Element Task Time Notes (M-W-A Time)1 2No. Element Task Total TIME OBSERVATION WORKSHEET Part Number Operation Number Rev. Letter Sum. Letter Operator1. Fill in all information 5. Make multiple time observations 2. Observe operator & record tasks 3. Record elapsed time in upper square - start at zero 4. Record task time in lower square 6. Use 2nd lowest time for task 7. Record * Auto Times * Non repeatable Tasks * Observations * Opportunities for waste reduction 8. Compute total times 舒仗仂仍仆亳亠 亟舒仆仆亠 于于亠 弍仍舒仆从舒 舒弍仍ﾐ莞夷膏亠 亰舒 仂仗亠舒仂仂仄 亳 亰舒仗亳亳亠 亰舒亟舒仆亳 Observe operator and record tasks 3. Record elapsed times in the upper squares (start with zero)/舒仗亳亳亠 亳亠从亠亠 于亠仄 于 于亠仆亳 从于舒亟舒舒 (仆舒仆亳亠 仆仍) 4. Record task times in lower square 舒仗亳亳亠 于亠仄 于仗仂仍仆亠仆亳 亰舒亟舒仆亳 于 仆亳亢仆亠仄 从于舒亟舒亠 5. Make multiple observations 亠亟亳亠 从仂仄仗仍亠从仆亠 仆舒弍仍ﾐ莞黍出狐 6. Use second lowest time 仗仂仍亰亶亠 于仂仂亠 仆亳亢仆亠亠 于亠仄 8. 仂亳舒 仂弍亠亠 于亠仄 7. 舒仗亳 ∃夷珂仂于亠仄 ∃亠 仗仂于仂ﾑ亳亠 亰舒亟舒仆亳 ∃舒弍仍ﾐ莞黍出狐 ∃仂亰仄仂亢仆仂亳 仗仂 仂从舒亠仆亳 仗仂亠
- 20. Arkhipov PA, flw UTS-ACE Process Capacity Chart 亳舒亞舒仄仄舒 于仂亰仄仂亢仆仂亠亶 亠仆仂仍仂亞亳亠从仂亞仂 仗仂亠舒 1. Fill in top section/ 舒仗仂仍仆亳亠 于亠仆亳亠 舒亰亟亠仍 2. Record operations/ 舒仗亳亳亠 亟舒仆仆亠 仂弍 仂仗亠舒亳 3. Record times (manual external, manual internal, and auto) 舒仗亳亳亠 于亠仄 仗仂亠仂于 (仆仂亶 于仆亠仆亳亶, 仆仂亶 于仆亠仆仆亳亶 亳 舒于仂仄舒亳亠从亳亶) 4. Record time and frequency for tool changes/ 舒仗亳亳亠 舒仂 亳 从仂仂 亰舒仄亠仆 亳仆仄亠仆仂于 5. Make computations/ 仂亳亰于亠亟亳亠 于亳仍亠仆亳 6. Compute Process Capacity/ 亳仍亳亠 于仂亰仄仂亢仆仂亳 仗仂亠舒 Directions 从仂于仂亟于仂
- 21. Arkhipov PA, flw UTS-ACE Process Capacity Chart 亳舒亞舒仄仄舒 于仂亰仄仂亢仆仂亠亶 亠仆仂仍仂亞亳亠从仂亞仂 仗仂亠舒 PROCESS CAPACITY CHART PAGE______OF_______ NEW / REVISED DATE A B C D E F G H I J K MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO #PCS. TO TIME / PC TOT / PC TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D+E) (F / A) CHANGE CHANGE (H / I) (G + J) TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE GRAND TOTAL "REMARKS" COLUMN. 97600 55 10.9 520.9 38 Pcs. 840 min. / 50400 sec. 67 Pcs. 360 GRIND SLOT 526431 1 150 360 DEPARTMENT NUMBER / NAME Cell 9 CURRENT DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY 212 3 237.8 510 510 XXX XXX XXX 16055 15.3 315.3 237.8 5 390 SWECO 528520 16 330 GRIND SLOT 524100 1 204 3600 3804 444 114 5 150 150 300 300 840 439 600 120 5 158 3 300 GRIND RAIL 519866 1 396 43 439 105 6.3 318.3270 GRIND RAIL 517624 1 753.5 67 3 252 60 312 312 660 744 900 95 9.5 147 3 240 GRIND FLAT 528441 1 546 198 744 72 18.3 343.8190 GRIND PROFILE 519433 8 100 504 5 444 2160 2604 325.5 1320 100 XXX XXX XXX 402 3 170 DRILLING 5 HOLES 519553 1 60 40 100 95 9.5 125.5100 GRIND I.D. 519821 1 134 376 3 40 76 116 116 900 134 XXX XXX XXX134 XXX 134 3 75 MARK 526630 1 XXX 204 247204 204 XXX XXX CALC. / REMARKS PROCESS CAPACITY (AVAIL. TIME / K) 50 PREDICT 516008 1 204 XXX PART NUMBER 4059681 PART NAME Vane 亳舒亞舒仄仄舒 于仂亰仄仂亢仆仂亠亶 亠仆仂仍仂亞亳亠从仂亞仂 仗仂亠舒
- 22. Arkhipov PA, flw UTS-ACE Process Capacity Chart (cont.) 亳舒亞舒仄仄舒 于仂亰仄仂亢仆仂亠亶 亠仆仂仍仂亞亳亠从仂亞仂 仗仂亠舒 (仗仂亟.) Documents all interactions for the entire process to determine process capacity./ 舒亟仂从仄亠仆亳亶亠 于亠 于亰舒亳仄仂亟亠亶于亳 亟仍 仂仗亠亟亠仍亠仆亳 于仂亰仄仂亢仆仂亠亶 于亠亞仂 仗仂亠舒 PROCESS CAPACITY CHART PAGE______OF_______ NEW / REVISED DATE A B C D E F G H I J K MACHINE PCS. / WALK MANUAL MANUAL AUTO TOTAL TIME / PC TIME TO #PCS. TO TIME / PC TOT / PC TASK # DESCRIPTION OF TASK NUMBER LOAD TIME INT EXT TIME (D+E) (F / A) CHANGE CHANGE (H / I) (G + J) TOTAL NOTE: REVISE TIMES WHEN SIGNIFICANT IMPROVEMENTS ARE INCORPORATED. DOCUMENT THE REASON IN THE GRAND TOTAL "REMARKS" COLUMN. PART NUMBER DEPARTMENT NUMBER / NAME PART NAME CURRENT DAILY OUTPUT AVAILABLE TIME MAXIMUM OUTPUT PER DAY CALC. / REMARKS PROCESS CAPACITY (AVAIL. TIME / K) 1. Record all information 2. Record operations 3. Record operation times * Manual int = machine running * Manual ext = machine stopped * Auto time 4. Record tool changes * Times * Frequency 5. Compute * F - Total auto + ext. manual time * G - Total time per piece * J - Time per piece for tooling change * K - Total time per pc including tooling changes 6. Compute process capacity Process capacity = Available timer per day / total time per pc 亳舒亞舒仄仄舒 于仂亰仄仂亢仆仂亠亶 亠仆仂仍仂亞亳亠从仂亞仂 仗仂亠舒 1. 舒仗仂仍仆亳亠 于亠 亞舒 2. 舒仗亳亳亠 仂仗亠舒亳亳 3. 舒仗亳亳亠 仗仂亟仂仍亢亳亠仍仆仂 仂仗亠舒亳亶 - 仆仂亶 于仆亠仆亠亶= 仄舒亳仆 舒弍仂舒ﾑ -仆仂亶 于仆亠仆仆亳亶= 仄舒亳仆 仆亠 舒弍仂舒ﾑ - 仄舒亳仆 舒弍仂舒ﾑ 于 舒于仂仄舒亳亠从仂仄 亠亢亳仄亠 4. 舒亳从亳亶亠 仄亠仆 亳仆仄亠仆舒 - 于亠仄 亰舒仄亠仆 - 舒仂
- 23. Arkhipov PA, flw UTS-ACE Operation Bar Chart 亳仂亞舒仄仄舒 仂仗亠舒亳亶 Evaluates:/ 舒亢舒亠: Balance between operations/ 舒仍舒仆 于亠仄亠仆亳 仄亠亢亟 仂仗亠舒亳礆亳 Each operation vs. Takt time/ 亠仄 从舒亢亟仂亶 仂仗亠舒亳亳 于 舒于仆亠仆亳亳 于亠仄亠仆亠仄 丐舒从 Targets for improvements/ 丶亠仍亳 仗仂 仍亠仆亳 Operator/machine interaction/ 亰舒亳仄仂亟亠亶于亳亠 仂仗亠舒仂舒 亳 仄舒亳仆
- 24. Arkhipov PA, flw UTS-ACE Operation Bar Chart (cont.) 亳仂亞舒仄仄舒 仂仗亠舒亳亶 (仗仂亟仂仍亢.) 13 11 11 5 15 13 13 25 12 17 14 3 仂仗亠舒亳 10 仂仗亠舒亳 20 仂仗亠舒亳 30 仂仗亠舒亳 40 Time, sec 亠仄, 亠从. Auto 于仂 Manual int. 仆. 于仆. Manual ext. 仆. 于仆亠. Walk 仂亢亟亠仆亳亠 45 38 27 30 2 仗亠亠仂亟舒 T/T = 37 亠从
- 25. Arkhipov PA, flw UTS-ACE Operator % Load Chart 亳舒亞舒仄仄舒 亰舒亞亰从亳 仂仗亠舒仂舒 Evaluates:(亠仆亳于舒亠) Balance between operations (舒仍舒仆 仄亠亢亟 仂仗亠舒亳礆亳) Cycle time vs. Takt time (弌仂仂仆仂亠仆亳亠 于亠仄亠仆亳 亳从仍舒 亳 于亠仄亠仆亳 丐舒从) Targets for improvements (仂亰仄仂亢仆仂亳 亟仍 仂于亠亠仆于仂于舒仆亳) Bottlenecks (亠于舒从 亠仂于) Available resources (仂仗仆亠 亠)
- 26. Arkhipov PA, flw UTS-ACE Operator %Load Chart (cont.) (亳舒亞舒仄仄舒 亰舒亞亰从亳 仂仗亠舒仂舒 (仗仂亟仂仍亢亠仆亳亠)) 0 10 20 30 40 50 60 70 80 仗亠- 仗亠- 仗亠- 仗亠- D 仗亠- 亢亳亟舒仆亳亠 丱仂亟 仆仂亶 # operators per shift Total C/T T/T n shift T/T 2 仗亠亠仂亟舒 丐/丐
- 27. Arkhipov PA, flw UTS-ACE Standard Work Combination Sheet 仂仄弍亳仆亳仂于舒仆仆舒 于亠亟仂仄仂 弌舒仆亟舒仆仂亶 舒弍仂 Used to: / 仗仂仍亰亠 亟仍 仂亞仂. 仂弍: 1. Highlight idle time / 仄亠亳 于亠仄 仗仂仂 2. Recognize walking time of operator/ 仗亠亟亠仍亳 于亠仄 仂亢亟亠仆亳 仂仗亠舒仂舒 3. Display machine cycle time/ 舒亰亳 于亠仄 亳从仍舒 仄舒亳仆 4. Display the work sequence of the operator/ 舒亰亳 仗仂仍亠亟仂于舒亠仍仆仂 舒弍仂 仂仗亠舒仂舒 5. Graphically display operator sequence. A picture is worth more than 1000 words./ 舒亳亠从亳 仂舒亰亳 仗仂仍亠亟仂于舒亠仍仆仂 舒弍仂 仂仗亠舒仂舒. 束亳仆仂从 仂亳 弍仂仍亠, 亠仄 舒 仍仂于損.
- 28. Arkhipov PA, flw UTS-ACE Standard Work Combination Sheet (cont.) 仂仄弍亳仆亳仂于舒仆仆舒 于亠亟仂仄仂 弌舒仆亟舒仆仂亶 舒弍仂 (仗仂亟仂仍亢.) TASK TIME : 1 LINE = ________ MINUTES SECONDS PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE OPERATOR MANUAL PART NAME DEPARTMENT NUMBER / NAME PREPARED BY TAKT TIME AUTOMATIC WALK WAIT STANDARD WORK COMBINATION SHEET (SWCS) STEP NO. DESCRIPTION OF TASK PCS / LOAD MAN - MACH CAP MAN AUTO WALK TOTAL TIME PER PIECE VVVVVVVVVV USE MINUTES PER PIECE FOR STANDARD WORK DATABASE 仂仄弍亳仆亳仂于舒仆仆舒 于亠亟仂仄仂 弌舒仆亟舒仆仂亶 舒弍仂 (SWCS) 舒舒 亳 仆舒亰于舒仆亳亠 仗仂亟舒亰亟亠仍亠仆亳 仂仗亠舒亳亳 仗亠舒仂 亠仄 束丐舒从損 亳仆 弌亠从仆亟 舒丱仂亟 仂亞仂 亠仄 仆舒 仂亟仆 亟亠舒仍 亰舒仂亟仂于舒仆仂 仄亳仆 仆舒 仂亟仆 亟亠舒仍 亟仍 弍舒亰 亟舒仆仆 舒仆亟舒亳亰舒亳亳 舒弍仂
- 29. Arkhipov PA, flw UTS-ACE Glossary of Symbols 弍仆亠仆亳亠 亳仄于仂仍仂于 / 仗亠舒亳亳 /丐舒仆仗仂 /仂于亠从舒 /舒仗亳亳 于亠仄亠仆亳 仆 仂仗亠舒亳亶 /舒仗亳亳 于亠仄亠仆亳 舒于仂仄舒亳亠从亳 仂仗亠舒亳亶 仗仂仍亰仂于舒 亟仍 仂仄仗仍亠从仆仂亞仂 仍亳舒 弌舒仆亟舒仆 舒弍仂 弍仂亰仆舒亠仆亳亠 亟仍 弌舒仆亟舒仆仂亶 舒弍仂 于 仗仂亠亠 弌亳仄于仂仍 仂仗亠舒仂舒 仗仂仍亰仂于舒 亟仍: 亳舒亞舒仄仄舒 仗仂仂从舒 亟亠舒仍亳 /舒亟亠亢从舒 舒仗亳亳 于亠仄亠仆亳 仂亢亟亠仆亳 /亠仄 仂亢亳亟舒仆亳 仗亠舒仂, 仆舒弍仍ﾐ莞委ﾑ亳亶 亰舒 舒于仂仄舒亳亠从亳仄 亳从仍仂仄
- 30. Arkhipov PA, flw UTS-ACE Standard Work Combination Sheet (cont.) 仂仄弍亳仆亳仂于舒仆仆舒 于亠亟仂仄仂 舒仆亟舒仆仂亶 舒弍仂 (仗仂亟.) Example 亳仄亠 TIME PER PIECE (亠仄 仆舒 亟亠舒仍) TOTAL (仂亞仂) WAIT STEP NO. DESCRIPTION OF TASK PCS / LOAD MAN - MACH CAP MAN AUTO WALK TASK TIME : 1 LINE = ________ MINUTES SECONDS AUTOMATIC PART NAME DEPARTMENT NUMBER / NAME PREPARED BY TAKT TIME WALK STANDARD WORK COMBINATION SHEET (SWCS) 弌舒仆亟. 仍亳 从仂仄弍亳仆亳仂于舒仆亳 舒弍仂 PART NUMBER OPERATION NUMBER REV. LETTER SUM. LETTER DATE OPERATOR MANUAL VVVVVVVVVV USE MINUTES PER PIECE FOR STANDARD WORK DATABASE (仗仂仍亰亶亠 于亠仄 仆舒 亟亠舒仍 亟仍 弍舒亰 亟舒仆仆 舒仆亟舒亳亰舒亳亳 舒弍仂 1.Fill in information 仗亳亳亠 亟舒仆仆亠 For Std. Work Measurement Only 丐仂仍从仂 亟仍 仆仂仄亳仂于舒仆亳 弌舒仆亟舒仆 于亳亟仂于 舒弍仂 2. Insert task from time Observation/ 仗亳亳亠 亰舒亟舒仆亳亠 亳亰 于亠仄亠仆亳 仆舒弍仍ﾐ莞黍出狐 3. Fill in time and compute total time 仗亳亳亠 于亠仄 亳 于亳仍亳亠 仂弍亠亠 于亠仄 4. Set scale based on total time 丕舒仆仂于亳亠 从舒仍 亳仂亟 亳亰 仂弍亠亞仂 于亠仄亠仆亳 5. Takt time is RED line 亠仄 丐丐 从舒仆舒 仍亳仆亳 6. Graph according to legend 亰仂弍舒亰亳亠 亞舒亳亠从亳 于 仂仂于亠于亳亳 仍亠亞亠仆亟仂亶
- 31. Arkhipov PA, flw UTS-ACE The Problem Solving Process 仂亠 亠亠仆亳 于仂仗仂仂于 PROBLEM SOLVING PROCESS 仂亠 亠亠仆亳 于仂仗仂仂于 UTC
- 32. Arkhipov PA, flw UTS-ACE The Problem Solving Process 仂亠 亠亠仆亳 于仂仗仂仂于 PROBLEM SOLVING PROCESS 仂亠 亠亠仆亳 于仂仗仂仂于 丕仗舒于仍亠仆亳亠 仗仂亠仂仄 亳 弌亠亳亳从舒亳 丶丐亂亊 弌丐亂 舒仗仂 弌仂从舒亠仆亳亠 于亠仄亠仆亳 仆舒 仆舒仍舒亟从 仂于亠 5S 弌舒仆亟舒仆舒 舒弍仂舒 仆舒仍亳亰 亠舒从亳亳 仆从舒 弍舒仆仆舒 亠舒从亳 亠亠仍仆仂 QCPC 丿舒亞 1: 亟亠仆亳亳从舒亳 仗仂弍仍亠仄 亳 舒仆仂于从舒 仗亳仂亳亠仂于 仂仂亢亟亠仆亳亠 仗亠仆 亳仂亟仂于 舒亢亟仂亟仆亠于仆舒 亟亠亠仍仆仂 丿舒亞 2: 亠仗亠从仍仂仆仆仂 仆仂于舒 亳亳仆舒 仆舒仍亳亰 丿舒亞 3: 丕舒仆亠仆亳亠 仂亳弍仂从 弌仗仂仂弍 舒仆亠仆亳 仂亳弍仂从 丕亂丐丐: 丐乘 丶弌弌乘 个丐
- 33. Arkhipov PA, flw UTS-ACE Management Roles and Responsibilities 仂仍 亳 亰舒亟舒亳 从仂于仂亟于舒 Communicate vision to rearrange factory into cells/ 弍亢亟舒 仆舒弍仍ﾐ莞黍出狐 亟仍 仂亞仂, 仂弍 亠仂亞舒仆亳亰仂于舒 亰舒于仂亟 于 仗仂亳亰于仂亟于亠仆仆亠 亠亶从亳 Provide schedule information/ 亠亟仂舒于仍 亳仆仂仄舒亳 仂 亞舒亳从亠 Eliminate barriers to expedite machine moves and cross-training/ 丕舒仆 弍舒亠 亟仍 仂亞仂, 仂弍 弍仂 仗亠亠仄亠舒 舒仆从亳 亳 仗仂于仂亟亳 仗舒舒仍仍亠仍仆仂亠 仂弍亠仆亳亠
- 34. Arkhipov PA, flw UTS-ACE Understand capacity of each manufacturing line and know where bottlenecks are/ 亠仆亳于舒 仄仂仆仂 从舒亢亟仂亶 仗仂亳亰于仂亟于亠仆仆仂亶 仍亳仆亳亳 亳 亰仆舒, 亞亟亠 仆舒仂亟 束亰从亳亠 仄亠舒損 Teach SW principles to operators/ 舒从舒亰于舒 仂仗亠舒仂舒仄 仂 仗亳仆亳仗舒 SW Lead events to implement SW/ 丕仗舒于仍 仂弍亳礆亳 亟仍 仂亞仂, 仂弍 于仆亠亟亳 SW Specialists Roles and Responsibilities 仂仍 亳 亰舒亟舒亳 仗亠亳舒仍亳仂于
- 35. Arkhipov PA, flw UTS-ACE Pilot Roles and Responsibilities 仂仍 亳 亰舒亟舒亳 仗亳仍仂舒 Assist in documenting, mapping, and analyzing processes for optimization /仂仄仂亞舒 于 仂舒于仍亠仆亳亳 亟仂从仄亠仆仂于, 从舒 亳 于 舒仆舒仍亳亰亠 仗仂亠仂于 亟仍 亳 仂仗亳仄亳亰舒亳亳 Assist in application of continuous flow processes/ 从舒亰于舒 仗仂仄仂 于 仗仂亠舒 仗仂仂礌仆仂亞仂 仗仂仂从舒 Identify waste elimination opportunities and assist in elimination actions 仗亠亟亠仍 于仂亰仄仂亢仆仂亳 仗仂 仆亳亢亠仆亳 仗仂亠 亳 仗仂仂弍于仂于舒 亳 舒仆亠仆亳 Ensure work instructions are in place, current, and accessible to the workers/ 丕弍亠亟亳, 仂 舒弍仂亳亠 亳仆从亳亳 于仆亠亟亠仆, 仂仂于亠于ﾑ 亟亠亶于亳亠仍仆仂亳 亳 仆舒仂亟 于 亟仂仗仆 亟仍 舒弍仂仆亳从仂于 仄亠舒