Professional Documents
Culture Documents
APS Booklet English
APS Booklet English
APS Booklet English
Input Output
(resources) Method (results)
Customer Satisfaction
Man APS Employee Satisfaction
Material Profitability
Society/Community
Machine Benefit
several languages.
Shareholders through
profit and stock values.
or previous processes.
7. Unnecessary motion: Actions of
people or equipment that
do not add value to the job.
Over Production is the worst waste of all because it leads to more waste.
Planned
Opening time stop-
pages 6 big losses
Stop- Breakdown
Loading time Availability
pages Changeover
In order to follow up equipment performance, we use the O.E.E. indicator (Overall Equipment
Efficiency). O.E.E. is the rate between <<quantity of good parts produced>> and <<quantity of parts
theoretically producible>>, without any disturbation (breakdown, defects, minor stoppages, etc.)
In detail, we measure O.E.E. by multiplying:
•the availability rate (loading time / opening time)
•the performance rate (net operating time / loading time)
•the quality rate (valuable operating time / net operating time)
GEN-TP-002-C1.0-APS Booklet - 21 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
Pillars
Now that our foundation is complete we will start to build
the pillars of our house. The pillars must exist before we
build the roof.
Just-In-Time
The first pillar of our house is titled Just-In-Time.
The Just-In-Time pillar consists of 6 elements:
n Leveling & Capacity
n Continuous flow
n Pull system
n Takt time
Just-In-Time
n Frequent deliveries •Leveling &
Capacity
•Continuous flow
Standards
n Whatis needed
n When it is needed
n Amount that is needed
Heijunka
Demand Leveling
A.P.S.
Market Time
AAA
BBB ABC
CCC ABC
The old conventional organization
ABC
(Pull System)
Producing product as kanban
signaled by card customer.
GEN-TP-002-C1.0-APS Booklet - 30 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
Takt Time
The pace of production, takt time, is the time required to
produce a single component or an entire product in order
to meet and not exceed customer demand.
I E
2 Identify internal and
external operations.
3 Transfer internal to
external operations.
4 Decrease internal
operations.
Now, mixing product
A and product B on
the line is not
anymore a problem.
A
5 Decrease external
operations.
B
GEN-TP-002-C1.0-APS Booklet - 35 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
One Piece Flow
One Piece Flow is the most efficient way to manage manpower
and material resources. When using a one piece flow, each
operation must be balanced according to Takt Time.
The Benefits are:
n The inventory between each process can be eliminated (Less
Work in Process).
n Products are created one by one (Shortened lead time).
n When changing builds there is less product to purge (Improved
SMED).
n Product moves through the process in the same order it was
delivered (First in First out).
Standards
A B C
Supplier Autoliv Customer
Man
GEN-TP-002-C1.0-APS Booklet - 39 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
Quality Assurance continued. . .
Materials
In order to build quality Products we must have quality
materials. To do this we must involve the supplier in the early
phases of the development of our products. We have to
establish an ongoing partnership with our suppliers. With early
supplier involvement we have seen that we can continue to
improve our level of quality supplied to our customers at a
lower cost because we don not have to inspect, scrap material
or stop assembly lines.
AUTOLIV
SUPPLIER 1 SUPPLIER 2
Examples:
n Observe visual aspect
n Training and self-learning
n Analyze situations
n Ownership and responsibility
Examples
n Poka yoke built in
n Artificial vision
n Operator panel displays information
n Andon (light coding)
Poka Yoke
GEN-TP-002-C1.0-APS Booklet - 43 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
Quality Methods
Many methods could be used to build quality assurance
in our processes and products. We’ve already mentioned
Poka Yoke. Some others are:
n5 Why
n Pareto diagram
n SPC
n Quality Matrix
n Cause and effect diagram (fishbone diagram)
n Problem solving process
n FMEA
n PDCA Wheel
Where detected
actions to eradicate the
Station 1
Station 2
Diagonality
defect, but also to detect Matrix
at the exact place where
it was produced.
Station 9 T
Defect detected on station 9, but produced on station 2
GEN-TP-002-C1.0-APS Booklet - 48 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
Cause and Effect Diagram
The Cause and Effect Diagram is a tool to list the potential
causes to a problem. It is also referred to as the Ishikawa
or fishbone diagram. We write the effect in the head of the
fishbone. The different bones are dedicated to a category
of cause where the corelines are the main causes, and the
lines coming off those, are the subcauses:
Cause
Effect
Each parameter is given a value between 1 and 10, where 10 corresponds to high
probability and serious consequences. The result will be a number between 1 and
1000 and the potential problems with the highest RPN will be corrected first.
GEN-TP-002-C1.0-APS Booklet - 52 PRIVATE/PROPRIETARY - FOR INTERNAL USE ONLY
PDCA Wheel
The PDCA Wheel is a methodology to apply solutions to a
problem to ensure the problem will not occur anymore.
DMAIC workshop
Lower Limit
defect is used for Lower Limit
Bad process
High variability
improving existing Good Process
Low Variability
product/process.
6 Sigma can also
be used for new
Lower Limit Upper Limit ones, for that we Lower
Limit
Upper
Limit
use Design For
defect
Six Sigma (DFSS)
defect
workshop.
Low Sigma Level
-Flexible
ny E
pa mp
m loy
Co ee
s
s Profitability
r
e Competitiveness So
cie
tom Satisfaction ty
s
Cu
Employee
Just-In-Time Involvement
•Leveling & •Safety Quality First
Capacity /Ergonomy •Quality
•Flexibility
•Continuous flow
and assurance
•Pull system Motivation
•Takt time •Discipline to •Quality
•Frequent standards Methods
deliveries •Continuous
•Line concepts Improvement •6 Sigma
•Process and
-Flexible
result
capacity •Don’t judge!
-One Piece flow •Don’t blame!
Team Muda
5S Standards TPM
Work elimination