Flexible Equipment
In this new article in the series “little production system” we will have a view on equipments and machinery of your facility. Have fun reading and learning.
Definition
Flexible facilities are machines, equipment and installations that can be quickly and efficiently adjusted to the product-specific and logistical wishes of the internal and external customers.
The targets:
No set-up times for platform parts necessary
Customer-synchronous setup times for variant parts are realized
Decoupling of employees and device (binding factor direction 0.1) is realized
The loss of production during relocation of a flexible device is less then one shift
The flexible facilities consist of of autonomous, modular units, which can be converted or combined into production or assembly devices
Resources that are available under the flexible devices are interchangeable
In case of service and assemblies the components of flexible equipments are interchangeable in customer takt
Ensuring the customer synchronous delivery in the required quality from an economic point of view
Cost-effective solutions have advantages (low cost automation)
Key elements:
Set-up in takt
Requirements for the flexible operation
Facilities
Product quality
Costs / economic efficiency
Relocation flexibility
Binding factor (operator / equipment)
Autonomous units
Service friendliness
Work preparation
Provision of operating resources; supply and disposal
Manufacturing strategy by platform and variant parts
Design of devices and tools
Automation (low cost automation)
Key Performance Indicators (KPI)
Setup times
Binding factor
Moving time
Self assessing the levels of fulfillment according flexible equipment
Assess your set-up procedure - set up in takt
Level 1
Planned times are available, but not related to is-time. Setup sequence and duration are always different.
Level 2
Set-up analyses on bottleneck stations and nominal/actual comparisons are partially carried out. Setup times are reduced by setup preparation during machining and first piece inspection. There are setup standards for individual facilities.
Level 3
At all “A” facilities are set-up standards. Systems for fast Set-ups are developed and in pilot areas tested. A strategy for set-up in the team is introduced.
Level 4
At all manufacturing and assembly equipments are set-up/exchange standards. At all “A/B” facilities are scaffolding systems - as far as economical - introduced. High runner lines can be exchanged in customer takt (setup time < 5 Min.). SMED (Single Minute Exchange of a Die) is realized.
Level 5
No set-up times for platform parts. Customer-synchronous set-up times for variant parts. First piece quality without readjustment and test runs. Standardization of:
Facilities /Assemblies
Resources
Work processes (e.g. set-up, process chain).
All factories have problems, writes manufacturing executive Rob Tracy. Sooner or later, your plant will fall behind in on-time delivery, your workforce will lose morale and the production calendar will fill up with emergency “hot list” scheduling. Tracy points out that getting a factory back in shape may be hard, but it’s not complicated. He explains step-by-step how to identify weaknesses, set attainable goals, get the cooperation of the whole organization and make improvements that last.
Read more here.
Requirements for the operation of flexible equipment
Level 1
There are specialists for every equipment.
Level 2
Individual operators can operate several devices.
Level 3
Individual operators can operate and set-up several devices. A concept for the standardization of control panels has been developed.
Level 4
Individual operators can operate several devices. The standardization of the control panels for A-installations has been implemented.
Level 5
Extensive decoupling of operator and equipment. The standardization of the control panels has been implemented in all facilities.
Levels of product quality
Level 1
No process capability, therefore 100% testing.
Level 2
Partial process capability for final processes. Predominantly 100% testing for final processes. Machine capability is a criteria for new purchases.
Level 3
Process capability at all “A” equipments. Targeted measures (e.g. investments / tolerance defusing) to achieve process capability.
Level 4
Process capability on all “A/B” equipments. Targeted measures (e.g. investments/tolerance defusing) to achieve process capability.
Level 5
On all “A/B” machines CpK > 1.66 (no more random checks). Annual PPM halving on all “A/B” machines.
Costs and economic efficiency
Level 1
Cost allocation is inadequate. Cost accounting is not transparent.
Level 2
Cost accounting for individual processes is realized.
Level 3
Cost accounting for individual processes and direct support processes is implemented (-> extended profitability analysis).
Level 4
Cost accounting for individual processes, direct and indirect support processes is implemented (-> extended profitability analysis).
Level 5
Process cost accounting is realized.
Relocation flexibility
Level 1
Fixed, rigid facilities. There are sometimes no or only individual interfaces at the facilities (inside / peripheral). There are no connecting elements.
Level 2
Expenses for moving is high (10.000 EUR). Duration of the move is long (approx. 5 days). There are partly standardized fasteners. There is partly a supply grid for electrics.
Level 3
Relocation is more flexible due to standardized procedure (costs <7.500 EUR, takes about 2 days). There are technical standards for ...
Interfaces
Fasteners
Supply voltage
Network connection
Cooling and lubricating oil
etc.
“A” facilities are retrofitted - if economical.
New equipment is procured on the basis of the established standards.
Level 4
In the case of new buildings and conversions, grids for supply and disposal facilities have been implemented. “A-/B” facilities are - as far as economically feasible - designed to the specified standards retrofitted. A move costs < 5.000 EUR and takes about 1 day. New facilities do not require special foundations.
Level 5
The relocation of flexible facilities is realized in about 0.5 days.
Binding factor (operator/equipment)
Level 1
High runner line – 1,0
Small batch production: unplanned
Assembly: According to cycle compensation time in the assembly cycle
Level 2
High runner line – 0,8
Small batch production: planned for A-equipment
Assembly: Target: Tact compensation time goes towards 0
Level 3
High runner line – 0,5
Small batch production: planned for A- and B-equipment
Assembly: ongoing optimization
Level 4
High runner line – 0,3
Small batch production: C equipments have the binding factor of 0.0
Assembly: ongoing optimization
Level 5
High runner line – 0,1
Small batch production: ongoing optimization
Assembly: ongoing optimization
Autonomous units
Level 1
Rigid linking and integration of the units to form facilities (e.g. transfer lines, special machines, assembly lines). The functions of the equipment are constantly monitored by operators.
Level 2
High degree of electrical / mechanical linkage between the units and equipment. Pilot projects for unattended breaks have been implemented. “A” facilities are improved so that a customer takt can be produced without operator supervision.
Level 3
Depending on the situation, “A” equipment can be operated without automation and integrated additional equipment. “A” facilities run through during the breaks. In case of malfunctions, the equipment switches off automatically. End of cycle and malfunctions are indicated by optical and acoustic signals.
Level 4
Depending on the situation, “A/B” equipment can be operated without automation and integrated additional equipment. “A/B” equipment runs through during the breaks.
Level 5
Autonomous, modular units that can be combined as required to form production/assembly facilities.
Service friendliness
Level 1
Equipment is only repaired by specialists.
Level 2
Assemblies and components of the equipment are gradually being standardized.
Level 3
The quick exchange of assemblies and components is designed and tested in pilot cases.
Level 4
The quick exchange of assemblies and components is implemented for “A/B” installations.
Level 5
Assemblies and components can be exchanged in customer takt.
Work preparation
Level 1
Equipment is planned and procured by specialists.
Level 2
Workflow planning, work and time studies, NC programming, fixture and tool design, etc. by specialists. Selection and implementation of workshop-oriented NC programming systems.
Level 3
Planning and procurement of equipment with the involvement of all affected employees. First in-house developments of simple devices and creation of simple NC programs by the operator.
Level 4
Operators are involved in the work preparation and know the main and supporting processes. Operators are qualified to independently develop simple devices and tools and to create NC programs.
Level 5
Work preparation in the island team under consideration of the process chain. Operators independently develop simple operating equipment (low cost automation) and create NC programs.
Provision of operating resources, supply and disposal
Level 1
Central supply of resources and tool presetting. Central supply and disposal.
Level
Frequently used devices and tools are stored on the island.
Level 3
Devices for high runner parts are located decentrally in the immediate vicinity of the equipment. Decentralized tool dispensing systems have been developed and introduced in pilot cases. An emergency plan has been drawn up for the failure of central supply and disposal units.
Level 4
New operating resource supply concepts have been developed and tested in pilot cases for facilities that produce on demand. The flexibility of the equipment is supported by tool removal systems. The emergency concept for the central supply and disposal units has been implemented. Emergency plans have been drawn up for the individual areas.
Level 5
Equipment supply concepts for demand-driven equipment have been introduced. Production is ensured even if central supply and disposal units fail.
Manufacturing strategy by platform parts and variant parts
Level 1
No clear difference in demand-oriented control.
Level 2
Partial families formed as standard for...
High runner lines (consumption-controlled)
Residual production (demand-driven).
Level 3
The machine park is divided into high runner lines and remaining production.
Level 4
Platform parts and "One-Piece-Flow" for variant parts implemented.
Level 5
Limited "flexibility" with standard machine for platform parts. High "flexibility" (complete machining) for variant parts.
Design of devices and tools
Level 1
Devices and tools are designed for individual positions.
Level 2
Devices and tools are designed for families of parts and for one process.
Level 3
Devices and tools are designed for families of parts and for several processes.
Level 4
25 % of the jigs / tools are interchangeable among the equipment in the process chain.
Level 5
50 % of the jigs / tools are interchangeable among the equipment in the process chain.
Automation
Level 1
All variants up to the highest degree of automation available.
Level 2
Individual process-related automation is available, buffer size approx. 0.5 hours.
Level 3
30 % of the high runner lines are equipped with low cost automation. In small-batch production, automation adapted to the overall problem has been investigated and, where appropriate, implemented to 30 %.
Level 4
60 % of the high runner lines are equipped with low cost automation. In small-batch production, automation adapted to the overall problem has been investigated and, where appropriate, implemented to 60 %.
Level 5
100 % of the racing lines are equipped with low cost automation. In small-batch production, automation adapted to the overall problem is examined and, where appropriate, implemented 100%.