Lean MFG - See 2-3

1
INDU321
Lean Manufacturing
CHAPTER 2- LEARNING TO SEE

PART 3: WHAT MAKES A VALUE STREAM LEAN?
Kudret Demirli
Contents In Brief:
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 Overproduction
 Characteristics of a lean value stream
 Takttime
 Continuous flow
 Supermarket pull system
 pacemaker process
 Paced withdrawal
Overproduction
3
 Q: What types of waste do you see in the CSM?

 A: WIP & Finished Goods Inventories
 Q: What’s causing it?
 A: Batch production.
 When you produce in batches, you overproduce -
producing more (sooner) than is required by the next
process.
 The most significant source of

waste is overproduction.
Overproduction
4
 This is how traditional systems operate: We can see

the fundamental problems with mass (or “batch-
and-push”) production in the CSM: each process in
the value stream operates as an isolated island,
producing and pushing product forward according
to schedules it receives from production control
instead of the actual needs of the downstream
“customer” process.
Overproduction
5
 Overproduction causes all kinds of waste, not just

excess inventory and money tied up in that
inventory.
 Since the material output is not yet needed

(overproduction), it must be handled, counted,
stored and so on. This represent pure muda.
Overproduction
6
 Defects remain hidden in the inventory queues until

the downstream process finally uses the parts and
discovers the problem (which is by then extensive and
hard to trace).
 It also lengthens the lead time, which impairs the

flexibility to respond to customer requirements.
 As a result, while the value-added time for producing

one product is very short, the total time that product
spends getting through the plant (Lead Time) is very
long.
Overproduction
7
 To reduce that overly long lead time from raw

material to finished goods, you need to do more
than just try to eliminate obvious waste.
 While it is good to be aware of waste, the future

state designs need to eliminate the sources or “root
causes” of waste in the value stream.
Overproduction
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STOP Overproduction!
Produce only what’s need and

when needed.
Overproduction
9
 Once the problems of mass production can be seen

in a way that reveals those root causes, we can
work at finding original solutions.
Characteristics of lean value stream
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 All we are really trying to do in lean manufacturing

is to get one process to make only what the next
process needs when it needs it. We are trying to
link all processes, from the final customer to raw
material, in a smooth flow (continuous flow) that
generates the shortest lead time, highest quality,
and lowest cost.
 We will follow Toyota’s lead and use the guidelines

below to do this, but first we define Takt time.
Definition: Takt Time
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 “Takt time” is how often one product or part is consumed by

the customer, and hence the at which it should be produced to
meet customer demand. Takt is a German word which means
pace.
 Takt time is calculated by dividing customer demand per shift
(in units), into the available working time per shift (in seconds).
Your available work time per shift

Takt Time=
Customer demand rate per shift
Definition: Takt Time
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27000 sec
Takt time = = 60 seconds
460 pcs
 Customer is buying this product at a rate of one

product every 60 seconds – customer demand rate.
 Target rate for production (for a product and its
components.)
Lean Value Stream
13
 Now, we will follow Toyota’s lead and use the

guidelines below to generate a lean value stream.
Lean Value Stream
14
Guideline # 1: Produce to the Takt time

Guideline # 2: Develop continuous flow whenever possible
Guideline# 3: Use supermarkets to control production where
continuous flow does not extend upstream
Guideline # 4: Try to send the customer schedule to only one
production process
Guideline # 5: Level the production mix at pacemaker.
Guideline # 6: Level the production volume
Guideline # 7: Develop the ability to make “every part every
day” (then every shift, then every hour or pallet or pitch) in
fabrication processes upstream of the pacemaker process.
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Guideline# 3: Use supermarkets to control production
where continuous flow does not extend upstream
Guideline # 4: Try to send the customer schedule to only
one production process
Guideline # 7: Develop the ability to make “every part
every day” (then every shift, then every hour or pallet or
pitch) in fabrication processes upstream of the pacemaker
process.
1:produce to the takt time
16
 Takt time is used to synchronize the pace of sales, particularly at the

“peacemaker process” (defined later in this chapter). It is a reference
number that gives you a sense of the rate at which the process should
be producing.
 Producing to takt sounds simple, but it requires concentrated effort to:
 Eliminate causes of unplanned downtime.
 Eliminate changeover time in downstream, assembly-type processes.
 Provide fast response (within takt) to problems.
 In some industries, such as distribution, custom products, and process
industries, it can take some creativity to define units of customer
demand. One solution is to define a “unit” as how much work can be
done at the bottleneck process in a “takt” of say 10 minutes. Then break
your orders into units of this takt interval.
1:produce to the takt time
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Producing to the Takt:
1. Helps us set a production rate to match demand

rate.
2. Requires us to do this in the most efficient way
by eliminating waste.
Lean Value Stream
18

production process
2: Develop continuous flow (more in Chapter 3)
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whenever possible
 Continuous flow refers to one piece at a time, with
each item passed immediately from one process
step to the next without stagnation (and many other
wastes) in between.
 Continuous flow is the most efficient way to produce,

and you should use a lot of creativity in trying to
achieve it.
2: Develop continuous flow
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whenever possible, cont.
2: Develop continuous flow
21
whenever possible, cont.
 The mapping icon we use to indicate continuous flow
is simply the process box. In the future-state
drawing, each process box should describe an area
of flow.
 So, if you introduce more continuous flow in the
future state, then two or more current-state process
boxes would combine into one box in the future-
state map.
Lean Value Stream
22

production process
3: Use supermarkets to control production where
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 There are often spots in the value stream where continuous

flow is not possible and batching is necessary. There can be
several reasons for this including:
 Some processes operate at very fast or slow cycle times.

 Some processes need to changeover to serve multiple
product families (e.g. stamping or injection molding).
 Some processes, such as those at suppliers, are far away
and shipping one at a time is not realistic.
 Some processes have too much lead time or are too
unreliable to couple directly to other processes in a
continuous flow.
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 Always resist the temptation to schedule these processes

via an independent scheduling function, because a
schedule is only an estimate of what the next process
will actually need.
 Instead control their production by linking them to their

downstream customers (processes), most often via
supermarket-based pull system.
 Install a pull system where continuous flow is

interrupted (even when the upstream process must
still operate in a batch mode.)
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 A “production” kanban triggers production of parts, while a “withdrawal”

kanban is a shopping list that instructs the material handler to get and
transfer parts (see the Figure below).
26
 The “customer” process material handler comes to the supplier’s

supermarket and withdraws what is needed. These withdrawals
trigger the movement of pre-printed kanban (typically cards) from
the supermarket to the supplier process, where they are used as the
only production instruction for that process.
 The purpose of placing a pull system between tow processes is to

have a means of giving accurate production instruction to the
upstream process, without trying to predict downstream demand
and scheduling the upstream process.
 Get rid of those elements of your MRP that try to schedule the
different areas of the plant. Let the downstream process
withdrawals out of a supermarket determine what the upstream
process produces when and in which quantity.
27
 The supermarket icon is open on the left side, facing the

supplying process. This is because this supermarket
belongs to the supplying process and is used to
schedule that process. On the factory floor,
supermarkets should ordinarily be located near the
supplying process to help that process maintain a visual
sense of customer usage and requirements.
 Pull systems are a nice way to control production

between processes that cannot be tied together in a
continuous flow.
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29
FIFO lanes
 Sometimes it might be more appropriate to use a FIFO (first-in, first-out) lane
between decoupled processes instead of a supermarket to maintain a flow between
them.
 FIFO lane is like a chute that can hold only a certain amount of inventory, with the
supplying process at the chute entrance and the customer process at the exit.
 Parts leave the chute in the same order that they went in (FIFO).
 If the FIFO lane gets full, the supplying process must stop producing until the customer
has used up some of the inventory.
 It may not be practical to keep an inventory of all possible part variations in a

supermarket - custom parts, parts that have a short life cycle, and costly parts that
are used infrequently (see two pages down for usage of FIFO).
 Or, you need to establish “sequenced pull” from an upstream process with short
lead time.
30
31
 Another example, you ship to an outside plating

process one time per day. The plater can only
handle 50 pieces per day, so you set up a FIFO
lane sized to hold at most 50 pieces of plating
work. In this manner, the FIFO lane prevents the
supplying process from overproducing, even though
the supplying process is not linked to the plater via
continuous flow or supermarket. When a FIFO lane
is full, no additional kanban are released to the
upstream process.
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 Supermarket :  FIFO Lane : Controlled

Controlled inventory (just inventory (required) fed
in case (waste)) - to downstream process
downstream process in a specific order.
pulls what it needs and
upstream process
produces what’s
consumed.
 FIFO is preferred to supermarket.

Lean Value Stream
33

production process
4: Try to send the customer schedule
34
to only one production process
 By using supermarket pull systems, you will typically need to send

the schedule to only one point in your door-to-door value
stream. This point is called the pacemaker process, because how
you control production at this process sets the pace for all
upstream processes.
 Because of this, the pacemaker process is frequently the most

downstream continuous flow process in the door-to-door value
stream. On the future state map, the pacemaker is the production
process that is controlled by the outside customer’s orders.
4: Try to send the customer schedule to
only one production process
35
4: Try to send the customer schedule to
only one production process
36
In the case of custom products, the scheduling point often needs to be

further upstream as shown below.
Note that material transfers from the pacemaker process

downstream to finished goods/customer need to occur as a flow
(no supermarkets or pull downstream of the pacemaker process).
Lean Value Stream
37

production process
5: Level the production mix at pacemaker
38
 Leveling the product mix means distributing the

production of different products evenly over a time
period. For example, instead of assembling all the
“Type A” products in the morning and all the “Type B” in
the afternoon, leveling the mix means alternating
repeatedly between smaller batches of “A” and “B”.
 Most assembly departments probably find it easier to

schedule long runs of one product type and avoid
changeovers, but this creates serious problems for the
rest of the value stream.
39
 Grouping the same products and producing them all at

once makes it difficult to serve customers who want
something different from the batch being processed.
This requires you to have more finished goods inventory
in the hope that you will have on hand what a customer
wants, or some lead time to fulfill an order.
 The more you level the product mix at the pacemaker

process, the more able you will be to respond to actual
customer requirements with a short lead time while
holding little finished goods inventory.
40
 This also allows your upstream supermarkets to be

smaller.
 However, be warned that leveling the mix requires

taking some pains in assembly such as more
changeovers and trying to keep all component
variations at the line at all times (to eliminate
changeover time).
 The reward is the elimination of large amounts of

waste in the value stream.
41
 The icon for production leveling is this symbol, which

is inserted into an information flow arrow.
Lean Value Stream
42

production process
6: Level the production volume
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 Too many companies release large amounts (batches) of work to their shop floor
processes, which causes several problems, such as:
 There is no sense of takt time (no “takt image”) and no “pull” to which the value
stream can respond.
 The volume of work performed typically occurs unevenly over time, with peaks
and valleys that cause extra burden on machines, people and supermarkets.
 The situation becomes more difficult to monitor: “Are we behind or ahead?”
 With a large amount of work released to the shop floor, each process in the
value stream can shuffle orders. This increases lead time and the need to
expedite.
 Responding to changes in customer requirements becomes very complicated,

which can often be seen in very complex information flows in current-state
drawings.
44
 Establishing a consistent or level production pace creates a

predictable production flow, which by its nature advises
you of problems and enables you to take a quick corrective
action.
 Regularly release only small, consistent amount of work

(usually between 5-60 minutes worth) at the pacemaker
process, and simultaneously take away an equal amount of
finished goods. We call this practice a “paced withdrawal”.
 We call the consistent increment of work “pitch”, and often

calculate the pitch increment based on packout container
quantity (the number of parts one finished-goods container
holds) or a multiple or fraction of that quantity.
45
 For example, if the takt time = 30 seconds, and the

pack size = 20 pieces, then the pitch = 10 minutes (30
sec  20 pcs = 10 minutes). In other words, every 10
minutes:
 a) Give the pacemaker process instruction to produce one
pack quantity.
 b) Take away one finished pitch quantity.
 In this case, pitch means multiplying your takt time

upward to a finished-goods transfer quantity at the
pacemaker process. This then becomes the basic unit of
your production schedule for a product family.
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 One way to think of pitch is as your “management time frame”.

How often do you know your performance to customer demand?
 If you release a week of work to the floor at one time, then the
answer is probably “once a week”. It is impossible to produce to takt
time in this situation - simply, there is no “takt image”.
 However, if you are scheduling and checking production every pitch,

then you can rapidly respond to problems and maintain takt time.
Just as we don’t want to transfer material in large batches, we don’t
want to transfer production instruction (information) in big batches
either.
 There are many ways to practice paced withdrawal of small,

consistent quantities of work. A tool used at some companies to help
both the mix and volume of production is a load-leveling (or
Heijunka) box.
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48
 A load leveling box has a column of kanban slots for

each pitch interval, and a row of kanban slots for each
product type. In this system, kanban indicate not only the
quantity to be produced but also how long it takes to
produce that quantity (based on takt time).
 Kanbans are placed (loaded) into the leveling box in the

desired mix sequence by product type (see the leveling
box illustration). The material handler then withdraws
those kanban and brings them to the pacemaker process,
one at a time, at the pitch increment.
49
Lean Value Stream
50

production process
7: Develop the ability to make “Every Part Every day” (then
every shift, then every hour or pallet or pitch) in fabrication
processes upstream of the pacemaker process.
51
 EPEi describes how frequently a process changes over to produce

all part variations.
 In general, we note either the batch sizes or “EPEI” in the data
boxes. EPEI stands for ‘Every Part Every Interval” – where interval
is replaced with a time such as week, day, shift, hour, pitch or takt.
 An initial goal at many plants is to make at least “Every Part Every
day” for high-running part numbers.
 By shortening changeover times and running smaller batches in
your upstream fabrication processes, those processes will be able
to respond to changing downstream needs more quickly. In turn,
they will require even less inventory to be held in their
supermarkets. This applies to both discrete-parts manufacturing
and process industries.

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1

CHAPTER 2- LEARNING TO SEE

 Supermarket pull system

 Q: What types of waste do you see in the CSM?

 The most significant source of

 This is how traditional systems operate: We can see

 Overproduction causes all kinds of waste, not just

 Since the material output is not yet needed

 Defects remain hidden in the inventory queues until

 It also lengthens the lead time, which impairs the

 As a result, while the value-added time for producing

 To reduce that overly long lead time from raw

 While it is good to be aware of waste, the future

Produce only what’s need and

 Once the problems of mass production can be seen

 All we are really trying to do in lean manufacturing

 We will follow Toyota’s lead and use the guidelines

 “Takt time” is how often one product or part is consumed by

Your available work time per shift

 Customer is buying this product at a rate of one

 Now, we will follow Toyota’s lead and use the

Guideline # 1: Produce to the Takt time

Guideline # 1: Produce to the Takt time

 Takt time is used to synchronize the pace of sales, particularly at the

Producing to the Takt:

1. Helps us set a production rate to match demand

Guideline # 1: Produce to the Takt time

 Continuous flow is the most efficient way to produce,

Guideline # 1: Produce to the Takt time

 There are often spots in the value stream where continuous

 Some processes operate at very fast or slow cycle times.

 Always resist the temptation to schedule these processes

 Instead control their production by linking them to their

 Install a pull system where continuous flow is

 A “production” kanban triggers production of parts, while a “withdrawal”

 The “customer” process material handler comes to the supplier’s

 The purpose of placing a pull system between tow processes is to

 The supermarket icon is open on the left side, facing the

 Pull systems are a nice way to control production

 It may not be practical to keep an inventory of all possible part variations in a

 Another example, you ship to an outside plating

 Supermarket :  FIFO Lane : Controlled

 FIFO is preferred to supermarket.

Guideline # 1: Produce to the Takt time

 By using supermarket pull systems, you will typically need to send

 Because of this, the pacemaker process is frequently the most

In the case of custom products, the scheduling point often needs to be

Note that material transfers from the pacemaker process

Guideline # 1: Produce to the Takt time

 Leveling the product mix means distributing the

 Most assembly departments probably find it easier to

 Grouping the same products and producing them all at

 The more you level the product mix at the pacemaker

 This also allows your upstream supermarkets to be

 However, be warned that leveling the mix requires

 The reward is the elimination of large amounts of

 The icon for production leveling is this symbol, which

Guideline # 1: Produce to the Takt time