Just about every operation that is implementing lean must deal with shared resources.  Supermarkets are used to signal these resources using a pull system.  However, Supermarkets are still inventory, and they prevent the Pacemaker from being established upstream.

In this advanced class on lean, delve into the newest techniques to implement Lean in the most difficult and complex environment - shared resources.  This workshop provides methods for moving the schedule point further and further upstream by learning how to flow parts through shared resources.  Learn the importance of dedicating parts to shared resources and looking upstream to determine what the product families could be.  Set intervals (EPEI) for shared resources and calculate branch takt times. Determine how to use multiple FIFO lanes to create continuous flow through shared resources.  Discover how to handle and batch processes such as heat treat ovens and variable rework flows along with Value Stream Management of shared resources.

The concepts covered in this workshop include:

• Dedicating parts to shared resources
• Setting intervals (EPEI) for shared resources
• Calculating branch takt time and average weighted cycle time using multiple FIFO lane systems to flow through shared resources dealing with rework
• Creating flight schedules to handle batch processes
• Scheduling and sequencing upstream resources
• Managing the flow through shared resources

What Participants Say

"This class was right on the mark!"

"This is the class I have been waiting for, and it delivered!"

"Our company is much more complicated than the ACME Stamping Company. Now we know what to do!"

"Our instructor was great! Very knowledgeable and practical!"

• Introduction
• Determining up-stream product families
• Exercise 1 - Sort part numbers into families. Using the data sheets provided in the workbook, determine the product families using the given upstream processes.
• Dedicating parts to shared resources
• Machine loading for shared resources
• Exercise 2 - Complete machine load calculations and load chart for a sample shared resource.

Factory Floor Activities - Afternoon

• Apply what was learned in the classroom and apply it on the shop floor. Activities include determining upstream product families based on the company’s products and processes, determining the ability to dedicate parts to shared resources, and calculating machine loading.

• EPEI analysis
• Exercise 3 - Complete an interval analysis and EPEI chart for a sample shared resource
• Branch takt time
• Average weighted cycle times
• Exercise 4 - Calculate the branch takt and the average weighted cycle time for a sample shared resource
• Creating flow through shared resources
• Multiple FIFO lane systems
• Exercise 5 - Design a multiple FIFO lane system for a sample shared resource

Factory Floor Activities - Afternoon

• Apply what was learned in the classroom and apply it on the shop floor. Activities include interval analysis, calculating branch takt time, and designing and handling multiple FIFO lane systems for a designated shared resource on the shop floor.

• Handling rework
• Handling batch processes
• Exercise 6 - Create a flight schedule for a heat treat shared resource
• Using the one-point schedule
• Sequencing with boxes and offsets
• Managing flow through shared resources
• Implementing pitch

Factory Floor Activities - Afternoon

• Apply what was learned in the classroom and apply it on the shop floor. Activities include creating flight schedules, and managing flow through shared resources for a designated shared resource on the shop floor.