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Alain Prioul
Flexibility / Adaptability
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Definitions
Flexibility
Ability to follow
customer demandat different Takt Time
Ability to quickly changefrom one part number to
another one
Adaptability
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Flexibility
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To reduce WIP + surface + handling + CAPEX
Key condition for high TRS
Key condition for levelling
To reduce lead time
Flexibility : Why ?
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t
Q
Average stockSafety stock
t
QA B C A B C A B C A B C A B C A B C A B C A B C
Stock level A
Production (batch size 2h)
12 h
Reduce inventories
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Safety stock t
Q
t
QA B C A B C A B C A B C A B C A B C A B C A B C
Stock level A
Production (batch size 2h)
12 h
Average stock
Reduce inventories
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100%
75%
18h
1h
5h
A
9h
B
9h
5h
P1
C
D
5h
P2
E
F
P3
G
H
P4 P(x)
TRS Increase
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10
9h
9h
5h
P1
2h
2h
5h
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
x2 x9
TRS Increase
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5h
9h
9h
5h
P1 P2 P3 P4 P5 P6
x2
2h
2h
2h
2h
2h
2h
2h
2h
2h
2h
2h
x9
TRS Increase
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12
9h
9h
5h
2h
2h
P1
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
x2 x9
2h
2h
TRS Increase
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13
9h
9h
5h
2h
2h
P1
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
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14
9h
9h
5h
2h
2h
P1
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
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15
9h
9h
5h
2h
2h
P1
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
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9h
9h
5h
2h
2h
P1
2h
2h
2h
2h
2h
2h
2h
P2 P3 P4 P5 P6
2h
2h
x2 x9
TRS Increase
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To reduce WIP + surface + handling + CAPEX
Key condition for high TRS
Key condition for levelling
To reduce lead time
Flexibility : Why ?
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Ideal condition:
Producing all products in parallel at TAKT TIME
(rhythm of customer demand of each part number)
Target : respect the TAKT TIME & full loading of the
equipment:
Producing all products in small batches close to TAKT TIME
Levelling
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Customer demand
Production = Large batches
Lead Time reduction
Production = small batches
Lead time
Lead time
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Adaptability :
Flexible Manpower Line
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Flexible Man Power Line : why ?
Work Contentchange
Customer demand change
n => n - 1
Takt Timechange
Result of Kaizen action
Work content mix
Work Content
Number of Operators =Takt Time
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Flexible man power line : Layout
U cell Linear (fixe)Unflexible
man power line
A
B C
D
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Flexible Manpower Line : Fundamentals
Linear lineconfiguration or U shapeline No barrierto operator movement
Line
Operator
Operators work insidethe cell
Operator loaded to takt time
Operation start and finish at the same point
One piece product flowby hand
Process
Standard in process stock Multi-process handling
Several Standard Workfor varying demand
Flexible working hours
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Flexible Manpower Line : Iso-productivity !
6 operators
PPH is constant
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- avoid overproduction => less WIP , space , handling
- smooth production => better usage of capacity
- smooth material flow => control lead time
- create standard conditions
- make kaizen possible
Flexible Manpower Line
Flexible Manpower Line
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