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Lean Manufacturing and Portable Metrology

Introduction to Lean Manufacturing, it's principles, and some lean manufacturing tools a company can implement to be efficient, including coordinate measuring machines.
by

Chad Crisostomo

on 20 June 2013

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Transcript of Lean Manufacturing and Portable Metrology

Purpose
To define what is Lean Manufacturing and its core principles
Sort
Straighten
Shine
Standardize
Sustain!
Clearly distinguishing what is necessary and disposing of the unnecessary
Organizing the necessary items so that they can be used and returned easily
Cleaning floors, equipment, and furniture in all areas of the workplace
Maintaining and improving the standards of the first 3 S's
Achieving the discipline of properly maintaining the correct 5S procedures and striving for continual improvement
Presented by:
Chad Crisostomo
Technical Product Manager (FaroArm)
FARO Technologies
Lean Manufacturing and Portable Metrology - Improving Manufacturing Efficiencies
Agenda
What is Lean Manufacturing?
Guiding principles of Lean Manufacturing
What are the Seven Deadly Wastes?
Lean Tools and Common Practices
FaroArm demonstration
What is Lean Manufacturing?
"....lean is not simply a toolbox, but a total perspective."
What is Lean Manufacturing?
A production practice and management philosophy focused on:
Optimizing customer value
Or in other words....
Making MORE with less!
This includes less manpower, less space, less material, less capital, and less time!
The Guiding Principles of Lean
1. Specify Value
What is the value of a specified product from the customer's perspective?
2. Identify Value Stream
What steps will create this value? What steps will create no value? What steps can be eliminated?
The Guiding Principles of Lean
3. Create Flow
Can we make our work elements flow continuously with minimal queues, no reworks and no stoppages?
4. Establish Pull
Can we deliver a value product desired by our customer exactly how they desire it and when they desire it?
The Guiding Principles of Lean
5. Seek PERFECTION
Now that we've identified value and produced a value product for our customer, is there room for improvement?

Can the process evolve?

Can we eliminate more waste?
"For improvement to flourish it must be carefully cultivated in a rich soil bed (a receptive organization), given constant attention (sustained leadership), assured the right amounts of light (training and support) and water (measurement and data) and protected from damaging*."
-Stephen Shortell, Ph.D.,
Professor of Organizational Behavior
What kind of damage is Dr. Shortell referring to?
The Seven Deadly Wastes (TIM WOOD)
Transportation
Inventories
Motion
Waiting
Over processing
Overproduction
Defects/Mistakes
These are activities that have been identified as non-value adding events or processes that hinder profitability in a company. They are:
The Seven Deadly Wastes
Transportation
Inventories
Motion
Waiting
Over Processing
Overproduction
Defects/mistakes
Time spent waiting idly for a process or task to finish
Using more energy than is required to produce a product (poor tool design)
Unnecessary movement of valued goods from one process to the next
Excess product (raw material or finished goods) waiting to be processed
Unnecessary movement or transportation of people and equipment due to an inefficient layout or process
Excessive operations resulting in making more parts than is required
Time spent repairing or reworking material
*
Now that we know what kind of activities to avoid, what are some of the lean tools at our disposal?
What is Cellular Manufacturing?
Arranging workstations in a sequence that promotes a smooth flow of materials through the production process with minimal wait or transport
Proven to be more flexible and responsive than the traditional mass-production line
Helps to eliminate overproduction, reduce defects and save floor space
In-line Inspection
What is In-Line Inspection?
Removes the need for separate testing and inspection labs
Decreases rework time and eliminates scrap
Allow workers to perform inspections directly on the line (in-process!)
Shopfloor Flow (After CM)
Parallel Solution
See the difference?
Shopfloor Flow (Before CM)
Shopfloor Flow (After Lean)
See the difference?
Shopfloor Flow (Before Lean)
Workplace Organization (5S)
A series of continuous activities for organizing a workspace for effectiveness and eliminating wastes that contribute to errors, defects and injuries
5S Cycle
Before and After examples:
Other notable examples:
A series of continuous activities for organizing a workspace for effectiveness and eliminating wastes that contribute to errors, defects and injuries
What is 5S?
Kaizen
What is Kaizen?
Focuses on eliminating waste, improving productivity and achieving sustaining improvement in processes of an organization
Key Kaizen elements include:
Relies on analytical techniques (such as the 5 Why's) to identify opportunities to eliminate waste in a specific process
Quality
Effort
Employee Participation
Communication
Willingness to Change
-The Gold Mine, by Michael and Freddy Balle
Create a plan for change, defining the steps you need to take to make the change
Carry out the plan in a test environment, under controlled conditions
Examine the results of the trial. Verify the process improved. If not, try again.
Implement the changes on a broader scale and update the standard operating procedures.
The Shewhart Cycle
"The most dangerous kind of waste is the waste we do not recognize." Shigeo Shingo, Toyota
Cellular Manufacturing
U-Shaped Solution
So how do portable CMMs fit into all this?
Portable Coordinate Measuring Machines
Typically 6 or 7 degrees of articulation resulting in flexibility within a volume
Quick and simple to use
Wireless (Wi-fi/Bluetooth) capabilities
Accurate up to 0.0125 millimeters
Can work in a wide range of environments
Various compatible probe sizes, including Renishaw Touch Probes
More about Coordinate Measuring Machines
Available in multiple lengths/ranges (from 4 feet to 300 feet)
Multiple mounting options
Compatible with leading inspection software packages such as Polyworks, Spatial Analyzer, Metrologic and Geomagic
Benefits include:
Efficient compared to hand tools = less measurement time!
Increased productivity and efficiency = less waste!
Check defects faster = less re-working!
Help create products quicker = less downtime!
Portable device = less space!
What is a Coordinate Measuring Machine (CMM)?
Device for measuring physical geometries of a part in 3 dimensions
Accurate up to one-millionth of a meter
Various sizes depending on the application
Size of the CMM in a facility
Working volume limited to size of the CMM bed
Cost
Limitations include:
Summary
Lean Manufacturing is a production process that can help save time, labor and money by eliminating waste
Lean tools such as 5S (workplace organization), cellular manufacturing and in-line inspection can help reduce harmful waste, thus improving product efficiency
Don't forget: Lean Manufacturing is a continual process. Always strive for perfection!
Brainstorm with other departments and evaluate every aspect of a process with the 5 Whys
Portable CMM's can help streamline both the manufacturing and quality aspect of a product, benefitting both the manufacturer and the customer
Thanks!
After the webinar:
Short 4 question survey when you exit
Follow-up email in a couple of days that will include a link to the recorded version of today's webinar
To show how portable coordinate measuring machines can contribute to Lean Manufacturing
To provide an understanding of Lean Manufacturing and its benefits to our industry
Achieving manufacturing excellence
Increasing efficiency
Eliminating "waste" (unnecessary activities that do not contribute to customer value)
Often considered to be the "building block" of all lean production methods
Live Demo!
Full transcript