Tuesday, November 16, 2021

Seven Flows of Manufacturing - Toyota Production System Industrial Engineering

 

Toyota Production System has a system or process design component and system and process improvement component. The Jidoka pillar of TPS describes these activities. The other pillar JIT deals with quantities of material flowing in the system. JIT is a small batch quantity production system.


Seven flows are important in process design and process improvement.


They are:


The flow of raw material

The flow of work-in-process

The flow of finished goods

The flow of operators

The flow of machines

The flow of information

The flow of engineering

Industrial engineers must first observe each of these flows to gain full understanding. Based on observation, they have to take notes and sketch out the seven flows. 

https://www.reliableplant.com/Read/19651/underst-implement-7-flows-of-manufacturing



OCTOBER 21, 2007 BY MARK

The Seventh Flow - The flow of engineering

http://theleanthinker.com/2007/10/21/the-seventh-flow/


Understand and implement the 7 flows of manufacturing.

Published on February 5, 2016

https://www.linkedin.com/pulse/understand-implement-7-flows-manufacturing-graham-chick/


Nakao-san and Shingijutsu-Kaizen

August 4, 2014 by Bob Emiliani

https://bobemiliani.com/nakao-san-and-shingijutsu-kaizen/


A kaizen method like no other!


Shingijutsu-Kaizen: The Art of Discovery and Learning describes how, for more than three decades, Kaizen consultants from Shingijutsu USA Corporation have been helping manufacturing and service organizations improve processes by teaching people the methods and tools of flow production.

https://bobemiliani.com/book/shingijutsu-kaizen/


http://www.shingijutsuusa.com/


Chihiro Nakao - Taiichi Ohno’s best student from outside of Toyota proper.

The Most Dangerous Idea in the World

By Jon Miller • Published: June 22nd, 2015

https://blog.gembaacademy.com/2015/06/22/the-most-dangerous-idea-in-the-world/


Nakao was in charge of development activities in a supplier company.

https://books.google.co.in/books?id=cNs_CQAAQBAJ&pg=PA13#v=onepage&q&f=false

Flow Analysis is part of Toyota Kaizen Course in 1968


Improving Flow - Lee Candy


Document or Map the process - Process Chart, Value Stream Map

Identify and log all problems the process owners/managers/engineers/operators experience

Identify all waste in the current process

Develop ideas for  improvement opportunities

Do engineering of improvement ideas

Develop Process Chart or Map of the Revised Process 

Develop an action plan to install the revised process

Actively monitor the new processes put into place to assure improvement expected.

Create performance measures for control in the operations

https://online.kettering.edu/news/2016/07/07/understanding-principle-flow-lean-manufacturing


A Toyota Leader on Misunderstandings About the Toyota Production System

By Mark Graban On Apr 24, 2019

It's a talk given by Nampachi Hayashi at the “Building on Success 2018 Conference.”

Mr. Hayashi says the name “should have been TPS = Toyota Process Development System.”

Built-in quality and improved flow leading to lower cost… as a result. Cost reduction isn't the primary lever that's pulled (as we see attempted in so many Western companies, including hospitals)… it's a result. Simple cost-cutting might not lead to better quality and flow (it's often quite the opposite that happens). But better flow and better quality always leads to lower cost, in my experience. Productivity is also a forward activity. It focuses on fully utilizing the machine and man to do a job with less resources. This it results in lower cost.



Discussion in LinkedIn Topic  https://www.linkedin.com/feed/update/urn:li:activity:6866080389295874048

When you talk about Flow - what else can be added to the information below!



Sivakumar Shanmugasundaram
https://www.linkedin.com/in/sivakumar-shanmugasundaram-84b9665a/

Operator flow .....

Are the operators knowledgeable about the process ?

Have the operators acquired the required skills to execute the work?

Is their fatigue level is same throughout the operating hours ?

Are they able to identify the defects ?

Are they able to identify the abnormalities in the machine ?

Are they able to measure and adjust the machine to produce zero defects ?


Material flow....

Is the material flow visible throughout the value stream ?

Is the material defect free ?

Is the material easy to handle ?

Information flow...

Does the right information reach the right person at the right time ?

What is the mode of information flow ?
verbal, hardcopies, or electronic

Has the receiver able to understand the information and execute effectively?



Ud 16.11.2021
Pub 3.5.2021













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