The cell manufacturing playbook: a step-by-step guideline by Chris A. Ortiz

By Chris A. Ortiz

Cell production takes conventional process-based creation environments and creates right-sized smaller paintings parts that experience all the crucial workstations and kit had to produce the product.

Until now, there was a necessity for a e-book with step by step guidance on the way to enforce phone production, often referred to as paintings cells. entire with colour photos, The telephone production Playbook: A step by step instruction for the tilt Practitioner fills this need.

This new booklet in The LEAN Playbook Series is perfect for Lean practitioners and facilitators searching for a coaching software that may be utilized in the paintings quarter whereas advancements are being made.

Like a soccer trainer, you should use this playbook for fast connection with express what’s had to facilitate powerful paintings telephone implementation. If for a few cause you put out of your mind a "play", you could simply reference the playbook. you could stick with web page via web page and use the playbook to facilitate winning paintings cells, otherwise you can pass on to convinced themes and use it that will help you enforce that exact "play."

The playbook comprises colour photographs, examples, and 3D versions from real paintings mobile implementations. as well as the photographs, a mix of brief paragraphs and bulleted issues stroll you thru the method of enforcing paintings cells to result in awesome alterations on your organization.

Although the ebook wastes little time on high-level thought, it does contain an introductory element that offers the root within the eight Wastes and Lean metrics had to totally take advantage of this playbook. assurance comprises time experiences, line balancing, regular paintings, unmarried piece move, takt time, and computer design.

Looking for supplemental details or Lean training from Chris Ortiz? visit to obtain ongoing aid and recommendation on find out how to use The LEAN Playbook Series for education and implementation.

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Page 17 shows the highlighted steps, and page 19 shows you the steps deleted. I ­discuss each removed step on page 20. 15 As you can see below, there are now 21 steps remaining from the original 34. These steps will not be needed in a cell manufacturing environment. It streamlines the work down to the value-added steps. There may be small amounts of non-value-added work but for the purposes of our work cell, most of it has been removed. See page 20 for more explanation. 68 Workload Balancing Non-Value-Added Work Content Elimination Walk and retrieve wire harness Stored in work cell Walk and retrieve main body sub-assembly Main body sub-assembly delivered (Kanban) Deliver to hardware work area Hardware station to be in work cell Walk and retrieve hardware from hardware storage Hardware stored in work cell Remove black grommets from bag and place in bin Removed by material handlers Deliver to assembly area Assembly station to be in work cell Walk and retrieve seat cushion Stored in work cell Check for burrs and deburr as needed Performed where I should (fabrication) Deliver to headlight work area Headlight station to be in work cell Walk and retrieve headlight sub-assembly from staging Headlight sub-assembly delivered (Kanban) Walk to retrieve LH panel from weld department LH panel delivered (Kanban) Walk and borrow air tool Tools at point of use in work cell Stage in work-in-progress (WIP) area for packaging Unchanged or a packaging station can be incorporated later into the work cell Some of the other Lean concepts that are applied to these wastes are reviewed in further chapters.

You will go into detail on Days 3 and 4 as the other part of Day 2 is to conduct a dry run to verify flow, time, and ­workload balancing. Day 2 of implementation: main floor items in place for dry run Implementation ◾ 41 Lift table going into place Workbenches going into place 42 ◾ The Cell Manufacturing Playbook (see above) A dry run is intended to verify the work cell setup, the time studies, and the line-balancing data. Place people in their positions and hand out the new standard work for each station.

Work Description: 3R Electric Bike Series Seq # Work Content VA St. 7 Station 4 Lift table and lazy Susan Compressed air lines Electrical lines Station light Communication lift Tool retractor 30 ◾ The Cell Manufacturing Playbook Items to Consider Antifatigue mats Mobile work cells: “train”-style movement Turntables Communication lights Rollers for moving in and out of stations Lift tables Tool retractors Work Cell Line Design ◾ 31 Station 1 Station 2 Parts Station 3 Operator Station 5 Station 4 System to Move Product into Next Station In our 3R Electric Bike example, each person is assigned to a workstation based on the work content established in the load balancing exercise.

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