E - II.2. Border of Line v12feb06
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• Logistics should supply containers closest possible to the operator´ s VAA; the
• Some containers can be placed by the operator in the VAA (if not possible to feed container the VAA border).
I.2. Border of Line
• Introduction; I. Production Flow • Diferent Types of Supply; • BL Organization;
5. Low Cost Automation 4. Smed 3. Standard Work 2. Border of Line 1. Layout and Line Design
13
3
4 5
Container on fixed shelf, fifo rack (kanban rack)
Pile of containers on a roller base Multi part container (Junjo KIT)
6
Inside trolley 7 8 Inside pallet size container 9 10 11 Detached 12 13
• Small Containers; • Special Containers for Big Parts; • Arrangement of Parts in Containers; • Single Feed of Parts;
• Trolleys and Rollers;
• Kit´ s of Parts; • Types of Containers Suitable for BL • Process for Defining Small Containers;
• Thermoformed inserts can be adapted to the shape of the part, and may form the container itself, but they require investment in special tooling; • Dunning in akilux or flat rigid material offers fast tool-free implementation; • With cardboard dunning, the container can be reused for other parts.
Border of Line (front supply w small containers)
2
Different Types of Supply
• Best layout for a workstation = operator always takes parts from the same location, with the shortest movement; • Consider 2 product types: A (x and a), B: (x and b); • Part x is used in all cases (common part), it is always on the workstation (Continuous Supply); • Parts a and b (product specific parts) can be:
600 x 400 400 x 300 300 x 200
European Standard
Area Heigth 120 235 320
600x400 20 litres 45 litres 60 litres
400x300 10 litres 20 litres
300x200 5 litres
7
Workstation Productivity Variable picking point (depends on product type)
• The choice between Continuous or Sequenced supply will impact workstation design; • Find the best solution after designing the Internal Supply System.
Special Containers for Big Parts
• For parts that are too long for a standard container, we can use longer containers, but still with the standard 400 mm width; • This makes it possible to use a standard frontal supply and storage infrastructure; • Standard lengths are 800, 1,000 and 1,200, for compatibility with transport dimensions.
Big containers (1 or 2 day WIP) Muda of movement No Std WORK Dificulty of Picking Average Balancing Bad FTQ at line end
Small/Specific containers (2 or 4h WIP) Std WORK LCA Mura Line Balancing Takt Levelling Std QUAL
3
Different Types of BL
1
Part arriving at BL BL type 1 2 Inside small container (smaller than 600x400) Placement in BL Pallet of small containers Container on fixed shelf, fixed rack
Back Supply
5
Small Containers
Large Container Reasons Small Container
Protection of Parts
Eliminate Muda of Movement
Logistics Flow
Ergonomy
6
Small Containers
• The number of different types of container must be reduced to a minimum, to optimize container management,; • Standard container sizes will maximize reuse on new product lines; • The world transport standard is defined by the useful truck width of 2.400 mm, which breaks down as 6x 400 or 4x 600; • Our basic container module dimension is therefore 600 x 400.
supplied on a continuous basis (Continuous or KANBAN supply); supplied in the sequence requested (Sequenced or JUNJO supply).
aaaaaaa Example bbbbbbb Type of Supply Frontal Supply Space occupied in BL Continuous (or Kanban Supply) Always the same part 1 location for each part number (SKU) Sequenced (or JUNJO Supply) Parts change according to product type 1 location for all part numbers Fixed picking point aaabbaaabbaaabb
60 cm
Flow of the main workpiece
60 cm
Flow of the main workpiece
ห้องสมุดไป่ตู้
70 cm
VAA – Value Adding Area
70 cm
• Use Frontal Supply of small containers whenever possible (with FIFO racks);
9
3
6
7
4
4
BL Organization
Border of Line is the interface between Production and Logistics operators. Their work should be completely separated. Frontal Supply
• How to Implement Small Containers.
Movie: BL Russia
Movie: Flow Cont. G.
1
Introduction
• The Border of the Line (BL) should be arranged in the best way to minimize MUDA of operators movement; • Usually big pallet loads are not accepted in the BL; • Small Containers or Trolleys should be used and placed on the best fixed location on the BL, preferably at operators hand reach (front supply).
Standard trolley
Part specific trolley Multi part trolley (Junjo trolley) Pallet size container Shelf, fixed rack Shelf, fifo rack (kanban rack) Part specific line trolley Part specific holder
• Use Back Supply of small containers or trolleys only when Frontal Supply is not possible (due to Product Volume); • “KIT supply” nearest to the VAA is the best supply in terms of Standard Work (Muda Elimination).
Part longer than 600 mm 800 x 600 containers encumber cell interior and are too wide for frontal supply 1,000 x 400 mm containers for wipers
600 1 000
1,000 x 400 container derived from two standard 600 x 400 containers
800 x 400 containers are compatible with standard supply dynamics
8
Arrangement of Parts in Containers
• Parts are arranged in the container to ensure adequate protection and precise, efficient picking and put-down; • The arrangement of parts in the container is determined naturally by the shape of the part, or imposed by means of dunning; • Dunning materials:
• Some containers can be placed by the operator in the VAA (if not possible to feed container the VAA border).
I.2. Border of Line
• Introduction; I. Production Flow • Diferent Types of Supply; • BL Organization;
5. Low Cost Automation 4. Smed 3. Standard Work 2. Border of Line 1. Layout and Line Design
13
3
4 5
Container on fixed shelf, fifo rack (kanban rack)
Pile of containers on a roller base Multi part container (Junjo KIT)
6
Inside trolley 7 8 Inside pallet size container 9 10 11 Detached 12 13
• Small Containers; • Special Containers for Big Parts; • Arrangement of Parts in Containers; • Single Feed of Parts;
• Trolleys and Rollers;
• Kit´ s of Parts; • Types of Containers Suitable for BL • Process for Defining Small Containers;
• Thermoformed inserts can be adapted to the shape of the part, and may form the container itself, but they require investment in special tooling; • Dunning in akilux or flat rigid material offers fast tool-free implementation; • With cardboard dunning, the container can be reused for other parts.
Border of Line (front supply w small containers)
2
Different Types of Supply
• Best layout for a workstation = operator always takes parts from the same location, with the shortest movement; • Consider 2 product types: A (x and a), B: (x and b); • Part x is used in all cases (common part), it is always on the workstation (Continuous Supply); • Parts a and b (product specific parts) can be:
600 x 400 400 x 300 300 x 200
European Standard
Area Heigth 120 235 320
600x400 20 litres 45 litres 60 litres
400x300 10 litres 20 litres
300x200 5 litres
7
Workstation Productivity Variable picking point (depends on product type)
• The choice between Continuous or Sequenced supply will impact workstation design; • Find the best solution after designing the Internal Supply System.
Special Containers for Big Parts
• For parts that are too long for a standard container, we can use longer containers, but still with the standard 400 mm width; • This makes it possible to use a standard frontal supply and storage infrastructure; • Standard lengths are 800, 1,000 and 1,200, for compatibility with transport dimensions.
Big containers (1 or 2 day WIP) Muda of movement No Std WORK Dificulty of Picking Average Balancing Bad FTQ at line end
Small/Specific containers (2 or 4h WIP) Std WORK LCA Mura Line Balancing Takt Levelling Std QUAL
3
Different Types of BL
1
Part arriving at BL BL type 1 2 Inside small container (smaller than 600x400) Placement in BL Pallet of small containers Container on fixed shelf, fixed rack
Back Supply
5
Small Containers
Large Container Reasons Small Container
Protection of Parts
Eliminate Muda of Movement
Logistics Flow
Ergonomy
6
Small Containers
• The number of different types of container must be reduced to a minimum, to optimize container management,; • Standard container sizes will maximize reuse on new product lines; • The world transport standard is defined by the useful truck width of 2.400 mm, which breaks down as 6x 400 or 4x 600; • Our basic container module dimension is therefore 600 x 400.
supplied on a continuous basis (Continuous or KANBAN supply); supplied in the sequence requested (Sequenced or JUNJO supply).
aaaaaaa Example bbbbbbb Type of Supply Frontal Supply Space occupied in BL Continuous (or Kanban Supply) Always the same part 1 location for each part number (SKU) Sequenced (or JUNJO Supply) Parts change according to product type 1 location for all part numbers Fixed picking point aaabbaaabbaaabb
60 cm
Flow of the main workpiece
60 cm
Flow of the main workpiece
ห้องสมุดไป่ตู้
70 cm
VAA – Value Adding Area
70 cm
• Use Frontal Supply of small containers whenever possible (with FIFO racks);
9
3
6
7
4
4
BL Organization
Border of Line is the interface between Production and Logistics operators. Their work should be completely separated. Frontal Supply
• How to Implement Small Containers.
Movie: BL Russia
Movie: Flow Cont. G.
1
Introduction
• The Border of the Line (BL) should be arranged in the best way to minimize MUDA of operators movement; • Usually big pallet loads are not accepted in the BL; • Small Containers or Trolleys should be used and placed on the best fixed location on the BL, preferably at operators hand reach (front supply).
Standard trolley
Part specific trolley Multi part trolley (Junjo trolley) Pallet size container Shelf, fixed rack Shelf, fifo rack (kanban rack) Part specific line trolley Part specific holder
• Use Back Supply of small containers or trolleys only when Frontal Supply is not possible (due to Product Volume); • “KIT supply” nearest to the VAA is the best supply in terms of Standard Work (Muda Elimination).
Part longer than 600 mm 800 x 600 containers encumber cell interior and are too wide for frontal supply 1,000 x 400 mm containers for wipers
600 1 000
1,000 x 400 container derived from two standard 600 x 400 containers
800 x 400 containers are compatible with standard supply dynamics
8
Arrangement of Parts in Containers
• Parts are arranged in the container to ensure adequate protection and precise, efficient picking and put-down; • The arrangement of parts in the container is determined naturally by the shape of the part, or imposed by means of dunning; • Dunning materials: