Lean Manufacturing Processes
Discussion
Does anyone else work in manufacturing?
We are attempting to get somewhere near this:
https://youtu.be/z66gH20uTZQ?si=LSxkEfKUQrItFdlC
We are attempting to get somewhere near this:
https://youtu.be/z66gH20uTZQ?si=LSxkEfKUQrItFdlC
Starfighter said:
What do you make?
What volumes are made?
Is there a cyclical variation in output?
What is the product mix/variety?
What is the driver for change? Lower cost? Lights out working? Cost down? All of the above?
Questions are all valid, we make thousands of parts, from individual components, to finished products, cnc machined, robot welded, assembled. Very similar to the video in a lot of ways.What volumes are made?
Is there a cyclical variation in output?
What is the product mix/variety?
What is the driver for change? Lower cost? Lights out working? Cost down? All of the above?
BGARK said:
Questions are all valid, we make thousands of parts, from individual components, to finished products, cnc machined, robot welded, assembled. Very similar to the video in a lot of ways.
What’s the problem you’re trying to solve for, and why do you think lean is the solution?LooneyTunes said:
What’s the problem you’re trying to solve for, and why do you think lean is the solution?
The problem, we have limited time on this planet, why waste it?Making things more efficient can only be a good thing, for example adding an automated welding station takes a 1 hour process down to a fraction of that. None of its easy initially to setup but the longer term gains are worth it. Hence the welding jig systems in that video were very interesting to me.
The Japanese are experts in this.
BGARK said:
The Japanese are experts in this.
I know. I’ve worked with some of the best of them in QA/SPC/6-sigma/lean in very high volume manufacturing environments. The reason for asking what the driver was is because you often find people latch on to, say, lean or six-sigma without really understanding why they want to use that methodology instead of others.
To take your example of the welding jig, that time saving is only worth it if the rest of your processes are up to it (I.e. you’re not going to be subject to or cause a bottleneck) and the cost to implement is appropriate. Usually you’ll the focus is on waste reduction and overall process efficiency rather than an outright quest for speed. That’s where the boundaries between methodologies can get confusing/interesting as, for example, a slower process with lower defect rates can be more efficient and/or profitable than faster one with higher defect rates.
It’s one area where getting a consultant in for a while can really pay off but a good one shouldn’t have a pre-determined view of the solution, should have multiple tools in their toolkit, and should be asking you what the problem is you want to solve/your objectives are before figuring out what the best overall approach is.
The big challenge often turns out to be that for any of the approaches to work well, you need to convince people that data is good/useful and find ways to 1) take appropriate measurements; and 2) turn data into useful, actionable, information.
BGARK said:
The problem, we have limited time on this planet, why waste it?
Making things more efficient can only be a good thing, for example adding an automated welding station takes a 1 hour process down to a fraction of that. None of its easy initially to setup but the longer term gains are worth it. Hence the welding jig systems in that video were very interesting to me.
The Japanese are experts in this.
What you are describing is fundamental good engineering practice. The whole point of engineering, indeed its very raison d'etre, is to make the most efficient use of resources for a given outcome, whether that's bridges, bicycles or moon rockets.Making things more efficient can only be a good thing, for example adding an automated welding station takes a 1 hour process down to a fraction of that. None of its easy initially to setup but the longer term gains are worth it. Hence the welding jig systems in that video were very interesting to me.
The Japanese are experts in this.
The Japs used to be the experts at production line efficiency 30 odd years ago, most of us still in business in the UK have caught up and sailed on past. Do you not have any Production Engineers?
Ean218 said:
What you are describing is fundamental good engineering practice. The whole point of engineering, indeed its very raison d'etre, is to make the most efficient use of resources for a given outcome, whether that's bridges, bicycles or moon rockets.
The Japs used to be the experts at production line efficiency 30 odd years ago, most of us still in business in the UK have caught up and sailed on past. Do you not have any Production Engineers?
Can I ask what you would call a production engineer, sorry if you think its a daft question but I am curious.The Japs used to be the experts at production line efficiency 30 odd years ago, most of us still in business in the UK have caught up and sailed on past. Do you not have any Production Engineers?
I have been in manufacturing engineering over 30 years and I have been doing supplier business assessments around 16 years for a multinational that are big on lean a value stream mapping..
Depending on where you are I would be happy to call in and walk the process. Send me a PM with an email on where you are etc. if you are interested.
Depending on where you are I would be happy to call in and walk the process. Send me a PM with an email on where you are etc. if you are interested.
BGARK said:
Can I ask what you would call a production engineer, sorry if you think its a daft question but I am curious.
The person who designs, and more often than not implements, the production process, usually a Chartered electro-mechanical Engineer of some sort. Not the sort of "engineer" who fixes a broken PC or does plumbing....Look at TV progs like Inside the Factory, whilst it is an awful format don't you just look in awe at how the production processes work? The guys who design those processes and machines that can flick badly cooked biscuits off the conveyor lines in microseconds are true production engineering geniuses.
Ean218 said:
The person who designs, and more often than not implements, the production process, usually a Chartered electro-mechanical Engineer of some sort. Not the sort of "engineer" who fixes a broken PC or does plumbing....
Look at TV progs like Inside the Factory, whilst it is an awful format don't you just look in awe at how the production processes work? The guys who design those processes and machines that can flick badly cooked biscuits off the conveyor lines in microseconds are true production engineering geniuses.
I fully agree, but qualifications alone don't always make these people, there is an innate ability in people on the spectrum to do this, mild autism helps, to see details that others miss, to suggest "flicky" mechanisms for biscuits. Myself and a couple of people in my team design products from scratch, and the processes that go along with them. We are all a bit different in our thought processes.Look at TV progs like Inside the Factory, whilst it is an awful format don't you just look in awe at how the production processes work? The guys who design those processes and machines that can flick badly cooked biscuits off the conveyor lines in microseconds are true production engineering geniuses.
BGARK said:
I fully agree, but qualifications alone don't always make these people, there is an innate ability in people on the spectrum to do this, mild autism helps, to see details that others miss, to suggest "flicky" mechanisms for biscuits. Myself and a couple of people in my team design products from scratch, and the processes that go along with them. We are all a bit different in our thought processes.
Well, you probably have to be "on the spectrum" to want to do any sort of engineering in the first place these days..... Particularly when you are involved in the repetition of a production plant. The qualifications teach you the things you cannot just pick up on the job.Ean218 said:
Well, you probably have to be "on the spectrum" to want to do any sort of engineering in the first place these days..... Particularly when you are involved in the repetition of a production plant. The qualifications teach you the things you cannot just pick up on the job.
Yes of course, degrees in engineering, process control and all manor of others are part of the course we undertook, I am older now, and did a full apprenticeship long time ago. Learning how to hand cut a block of metal squarely with a hacksaw for half a day is welded into the brain.BGARK, I've spent my working life in Kaizen and Lean consulting, would be more than happy to chat through what it means to really implement lean - drop me a PM if you'd like!
Keep in mind that these are tools and methodologies that drive business value - which is what aligns everyone to that way of thinking what makes it worthwhile. There's so much more to it than training a few people, or doing 5S... it's a business system and culture supported by top management to deliver their strategy.
Keep in mind that these are tools and methodologies that drive business value - which is what aligns everyone to that way of thinking what makes it worthwhile. There's so much more to it than training a few people, or doing 5S... it's a business system and culture supported by top management to deliver their strategy.
Twin2 said:
Venisonpie said:
Has anyone on here got experience of optimising food production processes? I'd be interested in thoughts on raw produce processing.
Hi, depends what you mean by optimise but I've done loads of work in chicken, potatoes, salads, chocolate etc... Happy to have a chat.Edited by Venisonpie on Tuesday 16th April 18:16
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