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Value Creation Through Integration Workshop A Framework for Integration from the Manufacturing Perspective Presented by: Tom Shields MIT January 30, 2002
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Value Creation Through Integration Workshop

Dec 08, 2016

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Page 1: Value Creation Through Integration Workshop

Value Creation Through !Integration Workshop !

A Framework for Integration from the Manufacturing

Perspective!!

Presented by:!Tom Shields!

MIT!

January 30, 2002 !

Page 2: Value Creation Through Integration Workshop

2 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Contents!

➢ Industrial product maturity impact on manufacturing!

➢ What is manufacturing system design!

➢ The manufacturing system design framework!

Page 3: Value Creation Through Integration Workshop

3 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Post Dominant Design Industrial Role!

➢ Product differentiation harder to achieve!➢ Product performance enhancements best

satisfied by incremental improvements!

➢ Acquisition and life cycle costs predominate!

➢ Insertion of process technologies has highest leverage!

Use Manufacturing for Competitive Advantage!

Page 4: Value Creation Through Integration Workshop

4 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

How can Manufacturing be Used for Competitive Advantage?!

➢ Product design alone is less of a discriminating factor for competitive success therefore …!➢ Design efforts should ensure producibility!➢ Manufacturing inputs should carry more weight !

➢ Process technology development yields most benefits!➢ Continual introduction of new processing

capabilities !➢ Organizational elements to champion process

developments!

Page 5: Value Creation Through Integration Workshop

5 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Elements for a Manufacturing System Design Framework !

➢  A holistic view of manufacturing system design environment!➢  Visual depiction of “design beyond factory floor” ideas!➢  Manufacturing as part of the product strategy!

➢  Manufacturing system design is strategy driven, not product design driven!

➢  Combines multiple useful tools!➢  Provides insights into order and interactions!➢  Not prescriptive!➢  Can lead to innovative & new manufacturing system designs!➢  Shows the unending design cycle -- Continuous Improvement !

Page 6: Value Creation Through Integration Workshop

6 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Manufacturing System Design!

1.  Manufacturing system “infrastructure” design!➢  Manufacturing strategy!➢  Operating policy!➢  Partnerships (suppliers)!➢  Organization structure details!

2.  Manufacturing system “structure” design!➢  Buildings, location, capacity!➢  Machine selection!➢  Layout!➢  WIP!

Manufacturing System Design

Tools

Manufacturing Strategy Tools

Page 7: Value Creation Through Integration Workshop

Stakeholders

Corporate Level

Business Unit

Product Strategy Suppliers Product Design Manufacturing Marketing

Requirements/Considerations/Constraints

Manufacturing System Design/Selection Implement (pilot) Evaluate/Validate Full Rate Production

[Interpret]![Seek approval]!

Mod

ifica

tions!Optimizing!

Manufacturing System Design !

`!

Society Employees Mgmt Govt. Suppliers Customers Stockholders

(Corporate Strategy)

(Business Strategy)

Page 8: Value Creation Through Integration Workshop

8 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Product Strategy!

Mar

ketin

g!

Product Design!

Manufacturing!

Supp

liers!

Product Strategy

PRODUCT PROCESS

SUPPLYCHAIN

Performance Specifications

Technology And process

Planning

Time,Space, andAvailabilityProduct

Architecture, andMake/buy

ManufacturingSystem, Make/buy

Recipe, UnitProcess

Details, strategy

Mar

ketin

g!

Product Design!

Manufacturing!

Supp

liers!

Product Strategy

Page 9: Value Creation Through Integration Workshop

Stakeholders

Corporate Level

Business Unit

Product Strategy Suppliers Product Design Manufacturing Marketing

Requirements/Considerations/Constraints

Manufacturing System Design/Selection Implement (pilot) Evaluate/Validate Rate Production

[Interpret]![Seek approval]!

DFMA,IPT!3-DCE!Concurrent Engineering!

•  VSM !•  Kaizen!•  Trial & Error!•  Kaikaku!

- Miltenburg, - 3P, - 2D plots, ! - MSDD, - AMSDD - design Kaizen!

Manufacturing System Design!

Mod

ifica

tions!

Fine Tune!

Finalized Product Design

Make/Buy!Risk-sharing Partnerships !

- Analytical Tools, !- Simulation Tools!

Customer Needs!Technical Feasibility!Feasible performance guarantees !

Page 10: Value Creation Through Integration Workshop

Stakeholders

Corporate Level

Business Unit

Product Strategy Suppliers Product Design Manufacturing Marketing

Requirements/Considerations/Constraints

Manufacturing System Design/Selection Implement (pilot) Evaluate/Validate Rate Production

[Interpret]![Seek approval]!

DFMA, IPT!3-DCE!Concurrent Engineering!

•  VSM !•  Kaizen!•  Trial & Error!•  Kaikaku!

- Miltenburg, - 3P, - 2D plots, ! - MSDD - AMSDD - design Kaizen!

Manufacturing System Design!

Mod

ifica

tions!

Fine Tune!

Finalized Product Design

Make/Buy!Risk-sharing Partnerships !

- Analytical Tools, !- Simulation Tools!

Customer Needs!Technical Feasibility!Feasible performance guarantees !

Page 11: Value Creation Through Integration Workshop

11 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

High Level Strategy Tools/Concepts!

➢  Focused Factory!➢ Wickham Skinner!

➢  Product-Process Matrix!➢ Hayes and Wheelwright!

➢  3-DCE!➢ Charlie Fine!

➢  Nine Components of Manufacturing Strategy!➢  Fine and Hax!

➢  Manufacturing Strategy Worksheet!➢ Miltenburg!

Page 12: Value Creation Through Integration Workshop

12 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Manufacturing System Design Tools!

➢ Axiomatic design/MSDD!➢ Cochran!

➢ Production Preparation Process (3P)!

➢ 2-D manufacturing world maps!➢ Toyota production system

frameworks!➢ Ohno, Shingo, and Monden!

➢ Various analytical tools/computer simulation tools!

Page 13: Value Creation Through Integration Workshop

13 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology!

Lean!Aerospace!

Initiative!

web.mit.edu/lean!

Conclusions!

➢  Manufacturing system design is more than the factory floor!

➢  Manufacturing system design is strategy driven !

➢  There is no one size fits all general manufacturing system design methodology !

➢  Best results realized by interacting with design, suppliers and marketing!

➢  Manufacturing is a competitive weapon in a maturing product industry!