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 !
A Framework for Integration from the Manufacturing
Perspective!!
Presented by:!Tom Shields!
MIT!
January 30, 2002 !
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!
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!
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!
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 !
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
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)
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
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 !
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 !
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!
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!
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!
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