HMLV Lean Questions - PCB manufacturing industry Value Stream Mapping

C

claymanz

#1
Hi there.
I am working in PCB manufacturing industry. It is somehow like a HMLV manufacturing. Therefore, I am wondering anybody can help on below questions when I do Value Stream Mapping:
1) Different products share same production line, how can I calculate the available time for the production line for 1 kind of product?
2) The P/N I am used in this process might not be the same P/N I used in next process as there are many P/Ns running in the production line. Is it okay for data collection from different P/Ns or do I need get a mean value from 5~10 samples?
3) Even for the products within one product group, they might have slightly different process flow (e.g. some of them have surface treatment in the middle of the process flow, some of them have surface treatment at the end of process flow), do I need distinguish them from each other when I perform VSM?
4) Is it possible for HMLV to implement Lean?
Thanks for your guys' help and looking forward for your reply!
:thanx:
 
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W

wmarhel

#2
1) Different products share same production line, how can I calculate the available time for the production line for 1 kind of product?
Take your total time and your total quantity by product (P/N). Determine what percentage of production is made up by each part and use that percentage to allot a period of time to it.

Product A: 100 pcs.
Product B: 200 pcs.
Product C: 100 pcs

Total Time: 480 minutes

Product A gets 120 minutes of available production time, Product B gets 240 minutes, etc. It will give you a starting point to begin massaging as needed.

2) The P/N I am used in this process might not be the same P/N I used in next process as there are many P/Ns running in the production line. Is it okay for data collection from different P/Ns or do I need get a mean value from 5~10 samples?
What exactly are looking at as far as data, takt time? Cycle Time?

3) Even for the products within one product group, they might have slightly different process flow (e.g. some of them have surface treatment in the middle of the process flow, some of them have surface treatment at the end of process flow), do I need distinguish them from each other when I perform VSM?
Yes, if it is significant, or it would cause you to not meet takt. If your below takt, then it isn't as important at this stage. Focus on something that is exceeding your allowable takt time.

4) Is it possible for HMLV to implement Lean?
Yes, you just need to be a little creative in your approach. Think about the concept and you could apply it to your situation. Don't try to take something right out of a book and attempt to apply it, you need to make it your own.

Wayne
 
C

claymanz

#3
First of all, thank you for such a detailed reply, Wayne. But I still got some questions to ask, can you help further?
Take your total time and your total quantity by product (P/N). Determine what percentage of production is made up by each part and use that percentage to allot a period of time to it.

Product A: 100 pcs.
Product B: 200 pcs.
Product C: 100 pcs

Total Time: 480 minutes

Product A gets 120 minutes of available production time, Product B gets 240 minutes, etc. It will give you a starting point to begin massaging as needed.
But the mix of products on this machine will change from time to time, do you think I need do weekly average or monthly average to make it typical?


What exactly are looking at as far as data, takt time? Cycle Time?
Yeah, the data like Change over time, Cycle time, etc. Need mean value from a few samples, right?


Yes, you just need to be a little creative in your approach. Think about the concept and you could apply it to your situation. Don't try to take something right out of a book and attempt to apply it, you need to make it your own.

Wayne
Do you have any readings or case studies for me to learn? I don't think I understand "Lean" thoroughly, what if my own way is wrong from the begining?

Thanks again for your kind help!:thanks::thanks:
 
W

wmarhel

#4
But the mix of products on this machine will change from time to time, do you think I need do weekly average or monthly average to make it typical?
Ideally, you should determine takt daily. I can't say for sure, but I would be willing to bet that are groups of parts that fall within 10-20% of each other as far as cycle time. For those parts that where the cycle is extreme from the rest of the population, you may need to come up with an alternative. If your only running a handful of parts with a lot of history, you could possibly determine takt farther in advance for planning purposes.

For instance, I once had a family of products made up of nine different sized units (Sizes 2-10). After all the various options/configurations, we had over 700 unique models that we might build. From an assembly line standpoint, we took all size 2 units, and sizes 8 through 10 off the main line and placed them on a secondary line (the volumes for these units also wasn't very high). The variance for the sizes 3 to 7 was <25 sec. Not perfect, but considering that I was able to reduce my overall cycle time by >30%, with half the WIP (work-in-progress) it was a definite improvement. This was also in a seasonal business, so it gave us the flexibility that we could reduce our finished goods requirements as well.

You need to do a spreadsheet of all the part numbers you'll run across this line/operation and try to identify product families and similar cycle times.

Yeah, the data like Change over time, Cycle time, etc. Need mean value from a few samples, right?
Yes, you'll want this data to help in creating the product families.


Do you have any readings or case studies for me to learn? I don't think I understand "Lean" thoroughly, what if my own way is wrong from the begining?

Two books I would recommend:

Implementing a Mixed Model Kanban System by Mike Vatalaro. Mike is a pretty sharp guy and this book will help answer a lot of your question regarding different products across the same line/process.

and

Creating Mixed Model Value Streams by Kevin Duggan. Another good book, and I think this too will help answer some your questions.

First, there is no "right" way to be lean or even to go about becoming lean. If you something isn't working, change it. Just be sure to take the time to learn why something does or doesn't work and modify accordingly.

Wayne
 
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