Vehicle Engine Overhauling Level III - Prevent and Eliminate MUDA PDF

HAWASSA POLYTECHNIC COLLEGE Vehicle Engine Overhauling Level III Unit of Competence: - Prevent and Eliminate MUDA MUDA 2 Outline: Part-1 Objective (goal or aim) Cost minimization The 3 M’s The 3 categories of operation The 7 Types of MUDA Part-2 How to Identify MUDA How...

HAWASSA POLYTECHNIC COLLEGE Vehicle Engine Overhauling Level III Unit of Competence: - Prevent and Eliminate MUDA MUDA 2 Outline: Part-1 Objective (goal or aim) Cost minimization The 3 M’s The 3 categories of operation The 7 Types of MUDA Part-2 How to Identify MUDA How to Eliminate MUDA 3  Objectives  This presentation aims is to create an awareness of wastes (MUDAs) in (7) forms.  At the end of the presentation, the participant should be able to: Describe waste and its concepts. Recognize waste, irregularity and strain in the organization that limit productivity and quality. Identify and eliminate 7-waste (MUDAs) Describe and ready for practical approach to conduct model KAIZEN activities 4  The concept of cost Cost minimization Determination of the sales price of the product Sales price=(manufacturing)cost + profit Manufacturing cost=(material + labor + facility + utility(machinery) + others)cost Company sets price(Demand>Supply) Traditional PRICE=COST + PROFIT Thinking Kaizen Thinking PROFIT= PRICE - COST Market sets price (Demand≤Supply) 6  Profit=Price- የትም ፍጭው ዱቄቱን አምጭው Cost Better Quality ምን ይሻላል??? On time Delivery M I Reasonable N Price I URE R M CT N UFA I MA Z Higher E CUSTOMER Profit COST 7  The Three M’s Definition of 3m’s Muda - ብክነት Muri -የስራ ጫና Mura ወጥ አለመሆን  The Three M’s muda mura muri freeleansite.com  The Three M’s Avoid these types of work Too much Imbalance(Mura) Excessive(Muri) Wasteful(Muda) Works Productivity improvement does not mean hard work 10  The Three M’s Muda Production factors that increase cost, in other words, all unnecessary things 11  The Three M’s (Cntd) Muri Mental and physical overburden on operators, and overburden on production machinery  The Three M’s (Cntd) Muri We should not force hard work on Employees in the name of productivity improvement Value added work Working density = Actual work 13 Muri : overburden Muri; overburden Muri over loded  The Three M’s Mura Variation in work distribution, production capacity of machinery, and material specifications 17 IN OUT  The three categories of Operations (1) Net Operation (value adding) (2) Non-Value adding Operations (3) “Muda” 20  Definition of value It is capability(power or ability to do something) provided to the customer at the right time at an appropriate price. It is defined by the ultimate end customer It is also product-specific 21  The three categories of Operations (1) Net Operation (value adding) Part of the operation that adds value to make parts and products Examples, Milling, Turning, Grinding, Assembling and Welding 22  የተጣራ የሥራ ሂደት [Net Operation] (value adding)  ይህ ኦፕሬሽን በማምረት ሂደት ውስጥ ለሚመረተው ምርት እሴት የሚጨምሩ ተግባራት ናቸው፡፡ ለምሳሌ ፤ ቁፋሮ, መጠገን፣ መሙላት፣ መፍጨት፣ ማጣበቅ፣ መስፋት፣ መለጠፍ፣ መቁረጥ፣ መበየድ፣ መገጣጠም፣ ማተም ወ.ዘ.ተ (2) Non-Value adding Operations Operation that adds no value but cannot be avoided Example Setting up, Inspecting, Picking up parts, Removing drill chips etc.. 24  በምርቱ ላይ ምንም እሴት የማይጨምሩ ሂደቶች [Non-Value adding Operations]  እነዚህ ሂደቶች በምርቱ(በስራው) ላይ ምንም እሴት የማይጨምሩ ሲሆኑ ነገር ግን አስፈላጊ የሆኑ ሂደቶች ናቸው፡፡ ለምሳሌ ፤ የጥራት ቁጥጥር ምርመራ፣ የምጠገኑትን ወደ ጥገና ክፍል መውሰድ፣ ብሎኬት ከተመረተበት ወደ ሌላ ቦታ መውሰድ ወ.ዘ.ተ. (3) “Muda” Muda is a Japanese word meaning Wasteful Activity Is anything unnecessary in operation. Can be eliminated immediately 26  ብክነት “Muda”  ብክነት ማንኛውንም በምርት ማምረት ሂደት ውስጥ የማያስፈልጉ እንዲሁም ዕሴት የማይጨምሩ አሠራሮች ናቸው፡፡ በሌላ መልኩ አላስፈላጊ የሆኑና ቶሎ መወገድ ያለባቸው አሠራሮች ናቸው፡፡ ለምሳሌ ፤ ከመጠን በላይ ማምረት፣ መጠበቅ ፣ ግድፈቶችን መስራት፣ ወ.ዘ.ተ.  በኛ በማታ ስልጠናውስ መስክ ………………………………………… “Muda” are activities which use resources, time or cost without adding value. Non-value adding Value adding movements assembling searching for tools molding transporting mixing materials building over production Cleaning waiting /idle time etc making defects etc 28  Very Simple Drill Operation to staple two papers using a stapler when work place is disorganized Materials and tools – Two pieces of paper – Stapler – Staples 29  Very Simple Drill Result in a disorganized environment N0. Activities Time Type of Measure How Operation 1 Searching for 35 Muda Eliminate 5S(Set-in- Stapler Sec order) 2 Searching for 30 Muda Eliminate 5S(Set-in Staples Sec order) 3 Putting the 8 Sec Non-Value Minimize Load staples Staples into the adding ahead stapler 4 Putting the two 3 Sec Non-Value papers adding - - together 5 Staple the papers 2 sec Net Operation (Value Adding) - - 30  ባልተደራጀ የሥራ ቦታ የሚኖረው ውጤት ተ.ቁ ተግባራት ጊዜ የኦፕሬሽን አይነት መለኪያ እንዴት 1 ሰቴፕለር መፈለግ 35 ሰከንድ ብክነት ማስወገድ 5ማ(ማስቀመጥ ) 2 የሰቴፕለር ሽቦ መፈለግ 30 ሰከንድ ብክነት ማስወገድ 5ማ(ማስቀመጥ ) 3 ሰቴፕለር ውስጥ ሽቦ ማስገባት 8 ሰከንድ በምርቱ ላይ ምንም እሴት የማይጨምሩ መቀነስ ቀድሞ ሽቦውን ማስገባት ኦፕሪሽን 4 ሁለቱን ወረቀቶች አንድ ላይ ማስቀመጥ 3 ሰከንድ በምርቱ ላይ ምንም እሴት የማይጨምሩ ኦፕሪሽን መቀነስ - 5 ወረቀቱን ማያያዝ 2 ሰከንድ የተጣራ የሥራ ሂደት (ዕሴት የሚጨምር) - - የኢትዮጵያ ካይዘን ኢንስቲትዩት 31  Lessons from the drill Can you imagine by how much the total time of the operation can be improved if we try to eliminate the Muda and minimize non value adding operations by applying 5S? What if the job order was to produce a car? Imagine the MUDA. 32  The Seven Wastes 1) “Muda” of Overproduction 2) “Muda” of Inventory COST COST 3) “Muda” of Waiting 4) “Muda” in Cost Reduction by Transporting Elimination of muda 5) “Muda” of Defect- making 6) “Muda” of Motion 7) “Muda” in Processing 33  Over Produced Motion 7 Categories of Transportation Waste Inventory Waiting Defect Making Over Processed 34  1)“Muda” of Overproduction To produce things more than necessary in terms of type, time, and volume. It is called “the worst kind of Muda” since it hides all the other wastes. 35  1)“Muda” of Overproduction [Cause] [Effect ] Excessive work Disturbance of flow force and Increase in facilities inventory Big lot Outbreak of defects production Deterioration of Big and fast turn-over ratio of production funds machine Advanced Lack of preparation of customer focus materials and parts36   2) “Muda” of Inventory The situation where items such as raw materials, parts, and finished goods are stagnant or which are not having value added to them. Some are located in the warehouses, and others are in-process inventory. 37  3) “Muda” of Waiting This includes all kinds of waste of time such as workers or parts waiting: -for an upstream process to deliver, -for a machine to finish processing, -for incoming parts or materials, -for process that has a long wait time 38  3) “Muda” of Waiting [Cause] [Effect ]  Bottle-neck processing stage  Waste of  Bad facility layout  Capacity imbalance manpower, time,  Big lot production & machines  Shortages & unreliable  Increase in the in- supply chain  Lack of multi-skilling process inventory  Ineffective production  Failed delivery planning dates  Poor workflow continuity 39  4) “Muda” in Transporting It is Unnecessary movement of parts between processes caused by unnecessary transportation distance, temporary storage, relocations or re- piling up. 40  4) “Muda” in Transporting [Cause] [Effect ]  Bad facility layout  Waste of space  Production deterioration  Big lot production  Expansion of  Single-skilled transportation workers facilities  Sedentary(not  Occurrence of scratches  Increase production moving)operation time  Low morale  wastes time and energy 41  5) “Muda” of Defect-Making This includes defects,  inspections for defects in-process, and claims, rescheduling, and resource loss. 42  5)“Muda” of Defect-Making [Cause] [Effect ]  Increase in material  Emphasizing on cost down-stream  Productivity processes by deterioration  Increase in personnel inspection & processes for  Poor in methods and inspection  Increase in defects standards for inspection and claims  Invite reworking  Lack of standard costs operation 43  6) “Muda” of Motion These are non-value adding movements or more than necessary movements of workers, equipment, and machines, such as looking for goods, bending, stretching, walking, lifting, and reaching etc. 44  6)“Muda” of Motion [Cause] [Effect ]  Isolated  Increase in operation manpower and  No education or processing training  Unstable  No standard operation operating  Increases procedure production time  Bad facility lay  Can cause injury out 45  7) “Muda” in Processing This consists of processing and operations primarily unnecessary. It is processing beyond the standard required by the customer. 46  7)“Muda” in Processing [Cause] [Effect ]  Lack of analysis of  Unnecessary processes or the contents of operation operation  Increase in  Improper tools and manpower and man- their use hour  Insufficient  Lower workability  Increase in defects standardization  Can reduce life of  Attitude - ‘Always components done it like this’. 47 The steps to effective waste elimination are 1. Make waste visible 2. Be conscious of the waste 3. Be accountable for the waste. 4. Measure the waste. 5. Eliminate or reduce the waste 48  5.How to eliminate “Muda”? 1) “Muda” of Overproduction Produce not more than is needed by your customers. you MUST know what your customers need and use. Have standardized work or work instructions for your processes. 49  5.How to eliminate “Muda”? 2) “Muda” of Inventory Implement 5S and avoid unnecessary items Use just-in-time system 3) “Muda” of Waiting Proper alignment of work processes, Consistent machine maintenance (to avoid machine downtime.) 50  5.How to eliminate “Muda”? 4) “Muda” in Transporting Design production lines and materials flow paths in a way that minimizes the distances between workstations and temporary storage sites. 5) “Muda” of Defect-making Build quality into each process, 51  5.How to eliminate “Muda”? 6) “Muda” of Motion Minimize unnecessary movements 7) “Muda” in Processing Improving processing efficiency to achieve the same customer satisfaction.  use of low-cost automation, smaller, and more flexible equipment 52  5.How to eliminate “Muda”? 7) “Muda” in Processing(Cntd) combining steps will greatly reduce the waste of inappropriate processing. Look for improvements Train workers 53  Tools for Eliminating “Muda” 1. Andon 2-U-line 3. In-lining 4. Unification 5. Multi-process handling & Multi-skilled Operators 6 -A.B. control (Two-Point Control) Cell production line 54  Tools for Eliminating “Muda” 1. Andon An “Andon” is an indicator informing team leaders and supervisors of the current workshop situation with color boards, flash lights, and automated announcement. 55  Tools for Eliminating “Muda” Types of “Andon” 1) Calling “Andon” a profession or occupation. -Used for requesting parts. (be said) be asserted or reported 2) Warning “Andon” -Used to inform occurrence of irregularities on the lines. 3) Progress “Andon” -Used to identify the progress of operation on the lines with a short Takt Time. 56  Tools for Eliminating “Muda” 2. U-line A U-line is a layout in which the inlet and outlet are positioned in the same direction to avoid walking back for a single operator. 57  Tools for Eliminating “Muda” 3. In-lining In-lining is a way to make the production lines simple and effective by integrating the parts processing into the main line in the unit production. 58  Tools for Eliminating “Muda” 4. Unification wuhedet Even if a flowing line cannot be formed, odd operations can be combined together in a place Unification of several into an operator’s processes work. 59  Tools for Eliminating “Muda” 5. Multi-process handling & Multi-skilled Operators Multi-process handling means that a single operator manages multiple machines and processes in product processing and assembling. This is the primary factor for constructing lines by a small number of operators. 60 Tools for Eliminating “Muda” A multi-skilled worker can deal with several machines or processes as described above. The supervisor can make a flexible placement of operators when someone within the same team or section is absent. 61  Tools for Eliminating “Muda” 6. A.B. control (Two-Point Control) A.B. control is a devised automatic control function. It controls the machine movement when they come to start or stop working depending upon the number of work pieces piled up between the preceding process and the following process. 62  Tools for Eliminating “Muda” 6. A.B. control (Two-Point Control)(Cntd) Up to Three A.B. control is used as a tool for time control to realize Just in Time(JIT) 63  Tools for Eliminating “Muda” 7.Cell production line This is a production line that a single operator manages all the machining or assembly operations in unit production. 64  Tools for Eliminating “Muda” 7.Cell production line(Cntd) Advantages Quality assurance can be ensured. The production output or efficiency of each operator can be clarified. Operators can obtain a feeling of work achievement. 65  To summarize The Customer should not pay any price for cost of wastes that we make. Therefore, it is us who have to make our products better in quality, deliver them on time and as the same time get more profit by eliminating MUDA. 66 THANK YOU 67