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Future State mapping, Page Four, Cell Production

 

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Cell production is now the favorite manufacturing system for low and medium volume production, the most important advantages are:

 

The implementation of cell production must be part of the design of the future state due to the advantages before mentioned.

As a simple example a conversion of two operations in our current estate map will be converted into a cell production system from the attribute boxes below and the data table from the previous sections.

 

 

      Cutting + Forming              Painting                        Assembly  +  Packing

1

Current State Attributes Boxes (Before Changes)
Cutting
Forming
Painting
Assembly
Packing
CT (Seconds)
50
20
40
45
40
CO (Minutes)
20
0
0
5
0
Avail(Seconds)
27600
27600
27600
27600
27600
Up Time (%)
95
100
100
96.70
100
Capacity (Units per shift)
524
1380
690
593
690
Cutting
Forming
Painting
Assembly
Packing
Current State Capacity (Units per shift)
524
1380
690
593
690
Future State Proposal
690
690
690
690
690
Current Main Power Vs Requirements
0.76
2.00
1.00
0.86
1.0
Man Power Shortage or Excess
-0.24
1.00
0.00
-0.14
0.00
The New Future and the Attributes for the Production Flow Will Be as Seen in the Table Below
Operations Cutting and Forming, now Combined into a new cell
Painting
Assembly and Packing now combined in a new cell operation
Required daily
production
690
690
690
The required CT(Seconds)
Max 38
CT= [(Available Time)X(up Time)]/690

       CT=(27600X0.95)/690
Max 38
Max 38
CO in minutes
10                
(It was 20 before improvements)                                                 
0
2
      (It was 5 before         improvements)
Available Time (Seconds)
27600
27600
27600
Up Time %
98
100
99.5
Actual new capacity
710(+3%)
690 (100)
722 (+5%)
Operators
1
1
2

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