New Approaches in Process

Improvement and Work Management

Chapters:
Part IV
20. Lean Production
21. Six Sigma and Other Quality Programs

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Lean Production
Sections:
1. Elimination of waste in production
Chapter 20 2. Just-in-time production
3. Autonomation
4. Worker involvement

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 What is Lean Production?
 Lean production means doing more work with
fewer resources
 Adaptation of mass production in which work is
accomplished in less time, smaller space, with
fewer workers and less equipment
 Based on the Toyota Production System

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Structure of Lean Production System

Taiichi Ohno's
structure of the
Toyota Production
System

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Activities in Manufacturing
1. Actual work
 Activities that add value to the product
2. Auxiliary work
 Activities that support the value-adding
activities
3. Muda (waste)
 Activities that neither add value nor
support the value-adding activities

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Muda (Waste)
Taiichi Ohno’s seven forms of waste:
1. Production of defective parts
2. Production of more parts than needed
3. Excessive inventories
4. Unnecessary processing steps
5. Unnecessary movement of people
6. Unnecessary handling of materials
7. Workers waiting

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Keys to Eliminating Waste
1. Just-in-time production
2. Autonomation (automation with a human
touch)
3. Worker involvement

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Just-In-Time Production
Production and delivery of exactly the required
number of each component to the
downstream operation in the manufacturing
sequence just at the moment when the
component is needed
 Minimizes:
 Work-in-process
 Manufacturing lead time

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Pull System of Production Control
 The order to make and deliver parts at each
workstation in the production sequence comes
from the downstream station that uses those
parts
 Alternative is a push system in which parts are
produced at each station irrespective of the
immediate need for those parts at the
downstream station

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Push System in Production Control

Upstream stations push work to the downstream station

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Pull System of Production Control

Downstream stations pull work from upstream stations

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Kanban System
 Toyota’s way of implementing a pull system
of production control
 Kanban means “card” in Japanese
 Two types of kanbans:
1. Production kanban – authorizes
upstream station to produce a batch of
parts
2. Transport kanban – authorizes transport
of the parts to the downstream station

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 20.3

Operation of
kanban system
between
workstations in
the Toyota
Production
System

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Setup Time Reduction
 Starting point in setup time reduction is
recognition that the work elements in setup
are of two types:
1. Internal elements – can only be done
while the production machine is stopped
2. External elements – do not require the
machine to be stopped

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 External Work Elements
 Can be accomplished while previous job is
still running
 Strategy: Design the setup tooling and plan
the changeover procedure to permit as
much of the setup as possible to consist of
external elements
 Examples:
 Retrieve tooling for next job from tool crib
 Assemble tools for next job
 Reprogram machine for next job

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Internal Work Elements
 Use time & motion study and methods
improvement to minimize the sum of the
internal work element times
 Use two workers rather than one
 Eliminate adjustments in the setup
 Use quick-acting fasteners rather than bolts
and nuts
 Use U-shaped washers instead of O-shaped
washers

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Examples of Setup Reduction
Setup time
Equipment type Before After Reduction

1000 ton press 4 hr 3 min 98.7%

Transfer line 9.3 hr 9 min 98.4%
Punch press 2 hr 3 min 97.5%
Machine tool 6 hr 10 min 97.2%
45 ton press 50 min 2 min 96.0%

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Effect of Setup Time Reduction
 Reduces production downtime, increases
machine utilization
 Reduces cost of changeovers
 Permits smaller batch sizes
 Reduces work-in-process inventory
 Allows greater flexibility in production
scheduling

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Other Requirements for JIT
 Production leveling - distribute changes in
product mix and quantity as evenly as possible
over time
 On-time delivery of components
 Defect-free components and materials
 Reliable production equipment
 Workforce that is cooperative, committed, and
cross-trained
 Dependable supplier base

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Autonomation
 “Automation with a human touch”
 Production machines operate autonomously as
long as they are functioning properly
 When they do not function properly (e.g., they
produce a defect), they are designed to stop

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Autonomation Topics
 Stop the process
 Error prevention
 Total Productive Maintenance (TPM)

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Stop the Process
 “Jidoka” – Japanese word meaning machines
that are designed to stop automatically when
something goes wrong
 Stop the process when:
 Defective parts are produced
 Required quantity has been completed
 Avoids overproduction

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Error Prevention
 “Poka-yoke” – Japanese word meaning
prevention of errors using low cost devices to
prevent or detect them
 Common mistakes in manufacturing:
 Omitting processing steps
 Incorrectly locating a part in a fixture
 Using the wrong tool
 Neglecting to add a part in assembly

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Poka-Yoke Functions
 Performs 100% inspection
 Stops the process when an error or problem is
detected
 Provides an audible or visible warning to alert
operator and other workers

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Total Productive Maintenance
 Goal: zero breakdowns
 TPM = integration of preventive and predictive
maintenance to avoid emergency maintenance
 Emergency maintenance = repair
equipment that breaks down
 Preventive maintenance = routine repairs to
avoid breakdowns
 Predictive maintenance = anticipating
malfunctions before they occur

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Availability Defined

Availability A = (MTBF - MTTR) / MTBF

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Availability Curve

Typical U-shaped availability curve for a piece of

equipment during its life
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Worker Involvement
 Continuous improvement
 Visual workplace
 Standard work procedures
 Total productive maintenance

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Continuous Improvement
 “Kaizen” – Japanese word meaning continuous
improvement of production operations
 Usually implemented by worker teams,
sometimes called “quality circles”
 Encourages worker sense of responsibility
 Allows workers to gain recognition among
colleagues
 Improves worker’s technical skills

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Visual Management and 5S
 Principle: the status of the work situation
should be evident just by looking at it
 Objects that obstruct the view are not
allowed
 Build-up of WIP is limited to a specific height
 Andon boards located above the assembly
line indicate the status of the workstations
 Worker training includes use of photos and
diagrams to document work instructions

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Worker Involvement through 5S

Japanese word English equivalent

Seiri Sort
Seiton Set in order, simplify access
Seiso Shine, sweep, scrub
Seiketsu Standardize
Shitsuke Self-discipline, sustain

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Standardized Work Procedures
Three components:
1. Cycle time – actual time required
 “Takt time” – reciprocal of demand rate
adjusted for available shift time
2. Work sequence – basically the same as
standard method
3. Standard work-in-process – minimum
number of parts to avoid waiting of workers

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Takt Time and Cycle Time
 Takt time defined
Ttakt = EOT / Qdd
where Ttakt = takt time, EOT = effective daily
operating time, Qdd = daily quantity demanded
 In the Toyota Production System, the work
must be designed so that the operation cycle
time is consistent with the takt time

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Standard Operations Routine Sheet
Shows the machines that must be visited by
the worker during each work cycle

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 U-shaped Work Cell
Allocation of work at nine machines between
three workers in a production work cell

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Operations Routine Sheets

Allocation of
work at nine
machines for
three workers
in a production
work cell

Work Systems and the Methods, Measurement, and Management of Work

by Mikell P. Groover, ISBN 0-13-140650-7.
©2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.