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Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,TenantsofSinglePieceFlow,DoNotMakeDefects,DoNotPassAlongDefects,DoNotAcceptDefects,ZeroDefects=0DefectsNot3.4ppm,Quality,Quality,QualityDefectsaretheWorstKindofWaste,7TypesofWaste,DefectiveParts,OverProduction,Inventory,Motion,Transportation,Waiting,ManualTouches,1,TenantsofSinglePieceFlowQual,Batch,Single Piece Flow,From:,The Toyota Production System,Building Quality into the Process,Single Piece Flow,The next process is the customer never send defects!,Sample Inspect catches Defect too Late,When you Finally Find a Defect,How many more do you have?,Where are they in the process?,What is the root Cause?,Single Piece Flow catches Defects immediately,When you find a Defect,You only have one,You know where it occurred,You Can find/Resolve the Root Cause immediately,2,BatchSingle Piece FlowFrom:Th,Check,Do,Verify,Check,-The previous operators work.,Do,-Your work.,Verify,-That you did your work correctly.,3,Check,Do,Verify3,Process,Inspect,Transport,Transportation is integrated into the production process,via automation e.g.,moving line,Process,Inspect,Process,Inspect,Transport,Process,Inspect,Transportation is integrated into the production process,via human conveyance e.g.,Chaku-Chaku,Building Quality into the Process,2 ways to perform SPF,The next process is the customer never send defects!,4,ProcessInspectTransportTranspo,Check,Do,Verify,Gets you into Parts Per Million quality-,When you verify your work,you catch 1 flaw in 100 parts.The next person checks your work and can catch 1/100 so thats 1/10,000.Then that person Verifies their work and can catch 1/100.Thats 1/1,000,000 errors that can get through.,5,Check,Do,VerifyGets you into,Check,Do,Verify,Every Customer in a Process has:,-a right to expect perfect material,-an obligation to inspect the material before use.,-an obligation to inform the previous step in the process of any problem.,-an obligation to stop the process until any problem has been resolved.,6,Check,Do,VerifyEvery Custome,Single piece or one piece flow is a means to primarily build,Quality into the process.This is achieved by establishing a takt,Time,developing std work,and swip.The premise is that an,Operator can only work on one piece at a time,and performs a,Quick quality check on the CTQs of the process before moving,The part to the following process.If a defect is detected,Jidoka,Is enactedthe line is stopped,and immediate action is taken,To remediate the situation and take countermeasures to prevent,reoccurence,Takt time,Std work,Flow:,work(process)that is done in conjunction with or,simultaneous to transportation,7,Single piece or one piece flow,One Piece Flow,The production is organized into a synchronous chain where each person has a,balanced,amount of work relative to his/her supplier and customer in the chain.,As one person finishes their element,so do all.Work is then moved down the line synchronously.,Every person is empowered to stop the production process if a reject is spotted.,8,One Piece Flow The production,Organization,Area,Supervisor,New/Rev,Page,of,Date,Production Line,Part Number,Part Name,Operator,Standard Work Sheet,To:,Turns,DPUs,Scope of Operations,From:,Quality,Check,Safety,Precaution,Standard,Work-in-Process,#Lots of,Standard,Work-in-Process,Takt/Rate,Time,Total Manual&Travel Time,Man/Travel Time,Operator,End Finish,Weld,End Finish,Weld,Orbital,Weld,Hydro Test,Mark,Mech.,Clean,Torch,Braze,Tubing,CFM Cell,Fern Bissonnette,Cell 6,All Parts,All Tubes,1 1,Mech.,Clean,Raw material,Weld,100/Day,FPI,X-Ray,EDM,2nd Qtr.01,End,Finish,Outside Cell,27-avg lot=6,Flex,Finished Goods,ACTION WORKOUT,g,GEMS Global Production System,The next process is the customer never send defects!,Check,Do,Verify,9,OrganizationAreaSupervisorNew,One Piece Flow,Your customer is the next step in the process.Give to your customer,exactly what they need(1 item),exactly when they need it,done perfect every time.,10,One Piece Flow Your custome,Tenants of 1 pcs Flow,Do Not Make Defects,Do Not Pass Along Defects,Do Not Accept Defect,Quality,Quality,QualityDefects are the Worst Kind of Waste,11,Tenants of 1 pcs FlowQuality,System of manufacturing in which the final process,withdraws the parts it needs from the preceding,process at exact timing intervals,in the exact,standardized amount needed.,Pull Production Methodology&Sequence,Definition,Ref,Material Presentation,training for explanation on Supermarket definition and use,12,System of manufacturing in whi,Parts,1,3,4,5,6,7,8,9,10,2,Assembly Line,Cell or Chaku-Chaku line,Supplier,Material,Information,Supermarket,Empty container,Full container,Legend,1,Sequence/Timing,Pull Production Methodology&Sequence,13,Parts13456789102Assembly LineC,JIT,Jidoka,e,GPS,for,GPC,Heijunka,Level Loading,Sequencing,Finding a balance between the volume of work that your organization needs to do and your capacity,Adjusting a production schedule to meet unex
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