1 Alain Prioul Flexibility / Adaptability

2 Definitions Flexibility Ability to follow customer demand at different Takt Time Ability to quickly change from one part number to another one Adaptability

3 Flexibility

4 To reduce WIP + surface + handling + CAPEX Key condition for high TRS Key condition for levelling To reduce lead time Flexibility : Why ?

5 t t Q Q ABCA t t Q Q 12 h Stock level A Production (batch size 12h) Safety stock Average stock Reduce inventories

6 t t Q Q Average stockSafety stock t t Q Q ABCABCABCABCABCABC ABCABC Stock level A Production (batch size 2h) 12 h Reduce inventories

7 Safety stock t t Q Q t t Q Q ABCABCABCABCABCABC ABCABC Stock level A Production (batch size 2h) 12 h Average stock Reduce inventories

8 t t Q Q t t Q Q Q Q t t Q Q t t Stock Average stock Safety stock Reduce inventories Production (batch size 12h) Q Q t t 12 h t t Q Q

9 100% 75% 18h 1h 5h A 9h B 9h 5h P1 C D 5h P2 E F P3 G H P4P(x) TRS Increase

10 9h 5h P1 2h 5h 2h P2P3P4P5P6 x2 x9 TRS Increase

11 5h 9h 5h P1P2P3P4P5P6 x2 2h x9 TRS Increase

12 9h 5h 2h P1 2h P2P3P4P5P6 x2x9 2h TRS Increase

13 9h 5h 2h P1 2h P2P3P4P5P6 2h x2x9 TRS Increase

14 9h 5h 2h P1 2h P2P3P4P5P6 2h x2x9 TRS Increase

15 9h 5h 2h P1 2h P2P3P4P5P6 2h x2x9 TRS Increase

16 9h 5h 2h P1 2h P2P3P4P5P6 2h x2x9 TRS Increase

17 To reduce WIP + surface + handling + CAPEX Key condition for high TRS Key condition for levelling To reduce lead time Flexibility : Why ?

18 Ideal condition: Producing all products in parallel at TAKT TIME (rhythm of customer demand of each part number) Target : respect the TAKT TIME & full loading of the equipment: Producing all products in small batches close to TAKT TIME Levelling

19 Customer demand Production = Large batches Lead Time reduction Production = small batches Lead time

20 Adaptability : Flexible Manpower Line

21 Flexible Man Power Line : why ? Work Content change Customer demand change n => n - 1 Takt Time change Result of Kaizen action Work content mix Work Content Number of Operators = Takt Time

22 Flexible Manpower Line A line which is designed in such a way that productivity is the same, whatever is the number of operators. Flexible Man Power Line : Definition Flexible Manpower System Optimizing labour productivity factory-wide by moving people from one flexible manpower line to another.

23 Flexible man power line : Layout U cell Linear (fixe) Unflexible man power line A B C D

24 Flexible Manpower Line : Fundamentals Linear line configuration or U shape line No barrier to operator movement Line Operator Operators work inside the cell Operator loaded to takt time Operation start and finish at the same point One piece product flow by hand Process Standard in process stock Multi-process handling Several Standard Work for varying demand Flexible working hours

25 Flexible Manpower Line : Iso-productivity ! 6 operators Demand - 15 % => 5 operatorsDemand - 30 % => 4 operators Demand - 50 % => 3 operators PPH is constant

26 - avoid overproduction => less WIP, space, handling - smooth production => better usage of capacity - smooth material flow => control lead time - create standard conditions - make kaizen possible Flexible Manpower Line

27 Investments TRS = 85% Vehicle life Vehicle quantity TRS = 100% Under-utilization Forecast Achieved

28 Investments Vehicle life Vehicle quantity All hands on deck ! Regular production 5 days a week Extra shift - Over Time Regular production 5 days a week kaizen Extra shift & over time

29 U-cells give the possibility to easily adapt floor space and labor requirements when volume changes occur Current Volumes 10% Decrease in Volume = 15% people less 25%drop of Volume = 30% people less 15% Increase in Volumes ‘ 40% Increase in Volume = 30% more people

30 Investments  Invest in simple, flexible and reliable equipment and prefer having two machines instead of just one.  In this case, each individual TRS will be higher and the payback will be better  Investments have to precedence to flexibility in order to reduce Capex, Stocks, Space, Handling A mean TRS of 85% is illusory for the life of heavy, dedicated equipment.