INSEAD Library

CD available inside back cover

Includes bibliographical references and index and glossary

Digitized

Creating Mixed Model Value Streams Practical Lean Techniques for Building to Demand Contents Foreword Preface Acknowledgments ix xiii xvii Part I: Introduction Getting Started Challenges of the Real Factory A New Look at These Challenges with Value Stream Mapping Where Do We Start? Welcome to EMC Supply Company Our Visit to EMC Supply Mixed Model Production 1 3 5 7 11 13 15 21 Part II: Product Families and The Pacemaker Question 1--Do We Have the Right Product Families? Product Families--A Closer Look Developing the Product Family Matrix at EMC Refining the Product Families The Current-State Map Developing a Future State Question 2--What Is the Takt Time at the Pacemaker? Takt Time Question 3--Can the Equipment Support the Takt Time? Cycle Time Question 4--What Is the Interval? Determining the Interval 29 31 31 33 37 44 44 49 50 55 56 61 65 Part III: Flow at the Pacemaker Question 5--What Are the Operator Balance Charts for the Products? What Time Do We Balance To? Creating Operator Balance Charts Balancing Machine Cycles Identifying the True Pacemaker Material Presentation Question 6--How Will We Balance Flow for the Mix? Balancing Products with High Work Content into the Family 73 75 78 79 85 87 89 93 93 Varying Labor--A Closer Look 100 Changeovers at the Pacemaker 104 Question 7--How Will We Create Standard Work for the Mix? 109 Documenting Standard Work 111 Visual Method Sheets 111 Smart Tools and Standard Work 113 Part IV: Pitch and Scheduling 115 Question 8--How Will We Create the Pitch at the Pacemaker? 117 Leveling Using Pitch 119 The Schedule Box 121 Creating Pitch at EMC Supply 126 Inverse Pitch 130 The Future State 131 Question 9--How Will We Schedule the Mix at the Pacemaker? 135 Mix Logic Charts 139 Creating the Mix Logic Chart at EMC Supply 141 Leveling the Mix 144 Loading the Schedule Box 146 The Future State 150 Part V: Customer Demand Question 10--How Will We Deal with Changes in Customer Demand? Smoothing Demand with Dynamic Supermarkets Determining the Starting Point The Future State 153 155 157 160 162 Part VI: Putting It All Together How Does It All Work? Running the Future State What's Next for the Team? 167 169 170 172 Appendices Appendix A: Lean Glossary Appendix B: EMC Supply Data Set Important Sources For Further Reading Index About the Author 175 177 185 189 190 191 205