Chapter 2 Industry.pdf

INDUSTRY 4.0
CHAPTER 2 : INDUSTRIAL ENGINEERING
(Lean Manufacturing)
EE014-3-1 – IND 4.0

Module Code and Module Title:EE014-3-1 IND4.0 Title of Slides: Lean Manufacturing
LEARNING OUTCOMES
What we will study?
➢ Concept of Lean Manufacturing - Content and technology within
Industry 4.0
a) Kanban/ Kaizen/ JIT
b) 7 tools of Quality Management
c) Six Sigma
d) Statistical Process Control (SPC)
e) Flexible Manufacturing Systems (FMS)
f) Manufacturing Execution Systems (MES)
g) Enterprise Resource Planning (ERP)

LEAN MANUFACTURING
“Becoming ‘lean’ is a process of
eliminating waste with the goal of creating
value.”

LEAN MANUFACTURING
• Arose in Toyota Japan as the Toyota Production System
• Replacing complexity with simplicity
• A philosophy, a way of thinking
• A process of continuous improvement
• Emphasis on minimising inventory
• Focuses on eliminating waste, that is anything that adds cost
without adding value

LEAN MANUFACTURING
https://www.youtube.com/watch?v=ZdHGTCXcJQU

LEAN MANUFACTURING

LEAN TOOLS - 5S

LEAN TOOLS - KANBAN

LEAN TOOLS - KAIZEN

LEAN TOOLS - JIT

Ishikawa’s Basic Tools of Quality
• Kaoru Ishikawa developed seven basic visual
tools of quality so that the average person could
analyze and interpret data.
• These tools have been used worldwide by
companies, managers of all levels and
employees.
https://www.youtube.com/watch?v=LdhC4ziAhgY

LEAN TOOLS -Seven Tools for Quality
Management
• Cause and Effect Diagrams
• Flow Charts
• Checksheets
• Histograms
• Pareto Charts
• Control Charts
• Scatter Diagrams

Purpose: Graphical representation
of the trail leading to the root cause of
a problem
How is it done?
• Decide which quality characteristic,
outcome or effect you want to
examine
• Backbone –draw straight line
• Big Bones – categories
• Medium size bones –secondary
causes
• Small bones – root causes
Cause & Effect Diagrams

Benefits:
• Breaks problems down into bite-size pieces to find root
cause
• Fosters team work
• Common understanding of factors causing the problem
• Road map to verify picture of the process
• Follows brainstorming relationship

Incorrect
shipping
documents
Manpower Materials
Methods Machine
Environment
Wrong source info
Wrong purchase order
Typos
Source info incorrect
Didn’t follow proc.
Glare on
display
No procedure
No communications
No training
Software problem
Corrupt
data

Histograms
Purpose:
To determine the spread or variation of a
set of data points in a graphical form
How is it done?:
• Collect data, 50-100 data point
• Determine the range of the data
• Calculate the size of the class interval
• Divide data points into classes
Determine the class boundary
• Count # of data points in each class
• Draw the histogram
Stable process, exhibiting bell shape
Histogram groups numbers into ranges and you can decide what ranges to use.

Histograms
Benefits:
• Allows you to understand at a glance the variation that exists in a
process
• The shape of the histogram will show process behavior
• Often, it will tell you to dig deeper for otherwise unseen causes
of variation.
• The shape and size of the dispersion will help identify otherwise
hidden sources of variation
• Used to determine the capability of a process
• Starting point for the improvement process

Histograms

Histograms
34

Scatter Diagrams
• Scatter Diagrams Defined
– Scatter Diagrams are used to study and identify the
possible relationship between the changes observed in
two different sets of variables.

Scatter Diagrams
• Constructing a Scatter Diagram
– First, collect two pieces of data and create a summary
table of the data.
– Draw a diagram labeling the horizontal and vertical axes.
• It is common that the “cause” variable be labeled on the
X axis and the “effect” variable be labeled on the Y
axis.
– Plot the data pairs on the diagram.
– Interpret the scatter diagram for direction and strength.

Scatter Diagrams
• An Example of When a Scatter Diagram Can Be Used
– A scatter diagram can be used to identify the relationship
between the production speed of an operation and the
number of defective parts made.

Scatter Diagrams
• An Example of When a Scatter Diagram Can Be Used (cont.)
– Displaying the direction of the relationship will determine
whether increasing the assembly line speed will increase
or decrease the number of defective parts made. Also, the
strength of the relationship between the assembly line
speed and the number of defective parts produced is
determined.
– Example obtained from:
<http://www.sytsma.com/tqmtools/Scat.html>

Scatter Diagrams

Checksheets
Purpose:
– Tool for collecting and
organizing measured or counted
data
– Data collected can be used as
input data for other quality tools
Benefits:
– Collect data in a systematic and
organized manner
– To determine source of problem
– To facilitate classification of data
(stratification)

45
Checksheets

46
Checksheets

Flow Charts
Purpose:
Visual illustration of the sequence of operations required to complete a
task
✓ Schematic drawing of the process to measure or improve.
✓ Starting point for process improvement
✓ Potential weakness in the process are made visual.
✓ Picture of process as it should be.
Benefits:
✓ Identify process improvements
✓ Understand the process
✓ Shows duplicated effort and other non-value-added steps
✓ Clarify working relationships between people and
organizations
✓ Target specific steps in the process for improvement.

Flow Charts - Top Down
Benefits
• Simplest of all flowcharts
• Used for planning new
processes or examining
existing one
• Keep people focused on
the whole process
How is it done?
• List major steps
• Write them across top of
the chart
• List sub-steps under
each in order they occur

Flow charts - Linear
Benefits
• Show what actually happens
at each step in the process
• Show what happens when
non-standard events occur
• Graphically display
processes to identify
redundancies and other
wasted effort
How is it done?
• Write the process step inside
each symbol
• Connect the Symbols with
arrows showing the direction
of flow
Toolbox

50
Flow charts

Flow charts - Linear

Flow charts

Pareto Charts
• Pareto Chart Defined
– Pareto charts are used to identify and prioritize problems
to be solved.
– They are actually histograms aided by the 80/20 rule
adapted by Joseph Juran.
• Remember the 80/20 rule states that approximately
80% of the problems are created by approximately 20%
of the causes.

Pareto Charts
• Constructing a Pareto Chart
– First, information must be selected based on types or
classifications of defects that occur as a result of a
process.
– The data must be collected and classified into categories.
– Then a histogram or frequency chart is constructed
showing the number of occurrences.

Pareto Charts
• An Example of How a Pareto Chart Can Be Used
– Pareto Charts are used when products are suffering from
different defects but the defects are occurring at a different
frequency, or only a few account for most of the defects
present, or different defects incur different costs. What we
see from that is a product line may experience a range of
defects. The manufacturer could concentrate on reducing
the defects which make up a bigger percentage of all the
defects or focus on eliminating the defect that causes
monetary loss.

Pareto Charts

57
Pareto Charts

Control Charts
• Control Charts Defined
– Control charts are used to determine whether a process
will produce a product or service with consistent
measurable properties.

Control Charts
• Steps Used in Developing Process Control Charts
– Identify critical operations in the process where inspection
might be needed.
– Identify critical product characteristics.
– Determine whether the critical product characteristic is a
variable or an attribute.
– Select the appropriate process control chart.
– Establish the control limits and use the chart to monitor
and improve.
– Update the limits.

Control Charts
• An Example of When to Use a Control Chart
– Counting the number of defective products or services
• Do you count the number of defects in a given product
or service?
• Is the number of units checked or tested constant?

Control Charts
61

Control Charts

SIX SIGMA

Module Code and Module Title:EE014-3-1 IND4.0 Title of Slides: Lean Manufacturing ‹#›

Chapter 2 Industry.pdf

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Chapter 2 Industry.pdf