091812 md faro webinar
TRANSCRIPT
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Presented By
Lean Manufacturing andPortable Metrology:
Improving ManufacturingEfficiencies
Chad Crisostomo
Technical Product Manager (FaroArm)
FARO Technologies
09/18/2012
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Purpose
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
To define what is Lean Manufacturing and its core principles
To provide an understanding of Lean Manufacturing and its benefits to our industry
To show how FARO can help contribute to Lean Manufacturing
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Agenda
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
What is Lean Manufacturing?
Guiding principles of Lean Manufacturing
What are the Seven Deadly Wastes?
Lean Tools and Common Practices
What are Portable CMMs?
Practical Applications and Case Studies
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What is Lean Manufacturing?
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
-The Gold Mine, byMichael and FreddyBalle
Lean is not simply a toolbox, but a totalperspective.
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What is Lean Manufacturing?
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Production practice and management philosophy focused on:
Optimizing customer value
Eliminating waste (unnecessary activities that do not contribute to customer value)
Increasing efficiency
Achieving manufacturing excellence
In other words, making more with LESS!
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The Guiding Principles of Lean
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
1. Specify Value
What is the value of a specified product from the customers perspective?
2. Identify Value Stream
What steps will create this value? What steps will create no value? What steps canbe eliminated?
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The Guiding Principles of Lean
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
3. Create Flow
Can we make our work elements flow continuously with minimal queues, no reworks,and no stoppages?
4. Establish Pull
Can we deliver a value product desired by our customer exactly how they desire itand when they desire it?
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The Guiding Principles of Lean
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
5. Seek Perfection!
Now that weve identified value and produced a value product for our customer, isthere room for improvement? Can the process evolve? Can we eliminate morewaste?
Of course!!!
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The Guiding Principles of Lean
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
"For improvement to flourish it must be carefullycultivated in a rich soil bed (a receptiveorganization), given constant attention (sustainedleadership), assured the right amounts of light
(training and support) and water (measurement anddata) and protected from damaging*.
*What kind of damage is Dr. Shortell referring to?
-Stephen Shortell, Ph.D.,Organizational BehaviorProfessor
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The Seven Deadly Wastes
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
The most dangerous kind of wasteis the waste we do not recognize.
-Shigeo Shingo, Toyota
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The Seven Deadly Wastes (TIM WOOD)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
The Seven Deadly Wastes areactivities that have beenidentified as non-value addingevents or processes that hinderprofitability in a company. Theyinclude:
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The Seven Deadly Wastes (TIM WOOD!)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
The Seven Deadly Wastes are activities that have been identified as non-value addingevents or processes that hinder profitability in a company. They include:
TransportationUnnecessary movement of valued goods from one process to the next
InventoriesExcess product (raw material or finished goods) waiting to be processed
Motionunnecessary movement or transportation of people and equipment due to aninefficient layout or process
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The Seven Deadly Wastes (TIM WOOD!)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
The Seven Deadly Wastes are activities that have been identified as non-value addingevents or processes that hinder profitability in a company. They include:
Waitingtime spent waiting idly for a process or task to finish
OverprocessingUsing more energy than is required to produce a product (poor tooldesign)
OverproductionExcessive operations necessary to produce a product, makingsomething before it is truly needed
Defects/mistakestime spent repairing or reworking material that could cause customerdissatisfaction
Now that we know what kind of activities to avoid,what are some of the lean tools at our disposal?
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Sustain!
Sort
Straighten
Shine
Standardize
What is 5S?
A series of activities for organizing awork space for effectiveness andeliminating wastes that contribute toerrors, defects and injuries
The stages are:
1. Sort: Clearly distinguishing what isnecessary and disposing of theunnecessary
2. Straighten: Organizing thenecessary items so that they canbe used and returned easily
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
3. Shine: Cleaning floors, equipment,and furniture in all areas of theworkplace
4. Standardize: Maintaining andimproving the standards of the first
3 Ss
5. Sustain: Achieving the discipline ofproperly maintaining the correct 5Sprocedures and striving forcontinual improvement
Sustain!
Sort
Straighten
Shine
Standardize
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Examples
Before After
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Examples
Before After
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Examples
Before After
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
More of Examples of
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Lean Tool Example: 5S (Workplace Organization)
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
More of Examples of
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Lean Tool Examples: Kaizen
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
What is Kaizen?
Focuses on eliminating waste,improving productivity and achievingsustaining improvement in processes ofan organization
Relies on analytical techniques (suchas the 5 Whys) to identify opportunitiesto eliminate waste in a specific process
Often considered to be the buildingblock of all lean production methods
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Lean Tool Examples: Kaizen
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Shewhart Cycle
One of the major components ofKaizen is the Shewhart Cycle.
The 4 stages are:
PlanCreate a plan for change,defining the steps you need to taketo make the change
DoCarry out the plan in a testenvironment, under controlledconditions
Shewhart Cycle
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Lean Tool Examples: Kaizen
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Shewhart Cycle
CheckExamine the results of thetrial. Verify the process improved. Ifnot, try again!
ActImplement the changes on abroader scale and update thestandard operating procedures.
Shewhart Cycle
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Lean Tool Examples: Kaizen
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Key Elements of Kaizen include:
Quality
Effort
Employeeparticipation
Communication
Willingnessto change
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Lean Tool Examples: Cellular Manufacturing
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
What is Cellular Manufacturing?
Arranging workstations in a sequencethat promotes a smooth flow ofmaterials through the productionprocess with minimal wait or transport
Helps to eliminate overproduction,reduce defects and save floor space
Proven to be more flexible andresponsive than the traditional mass-production line
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Lean Tool Examples: Cellular Manufacturing
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Shopfloor Flow (before CM)
1
3
5
6
Queue
Bench
4
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Lean Tool Examples: Cellular Manufacturing
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Shopfloor Flow (After CM)
1
3 4
6
U-Shaped Solution
1 3
456
Parallel Solution
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Lean Tool Examples: Cellular Manufacturing
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
What are In-line Inspections?
Removes the need for separate testing andinspection labs
Allow workers to perform inspections directlyon the line (in-process)
Decreases rework time and eliminates scrap
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Typical Batch Manufacturing (Before Lean):
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Queue Queue Queue Queue
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Test and Inspection Lab
Finished
Goods
Rework Area
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Queue Queue Queue Queue
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Finished
Goods
Rework Area Test and Inspection Lab
Typical Batch Manufacturing (Before Lean):
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Batch Manufacturing (After Lean):
Opn 1 Opn 2 Opn 3 Opn 4
Opn 1 Opn 2 Opn 3 Opn 4
Finished
Goods
In-Line Inspection =
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Batch Manufacturing (After Lean):
Opn 1 Opn 2 Opn 3 Opn 4
Opn 1 Opn 2 Opn 3 Opn 4
Finished
Goods
In-Line Inspection =
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Lean Tool Examples: In-line Inspections
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Opn 1 Opn 2 Opn 3 Opn 4
Opn 1 Opn 2 Opn 3 Opn 4
Finished
Goods
In-Line Inspection =
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Queue Queue Queue Queue
Opn 1 Opn 2 Opn 3 Opn 4 Inspect
Finished
Goods
Rework Area Test and Inspection Lab
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Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
So how do portable CMMs fit into all of this?
Wh t i C di t M i M hi (CMM)?
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What is a Coordinate Measuring Machine (CMM)?
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Device for measuring physicalgeometries of a part in 3 dimensions
Accurate up to one-millionth of a meter
Various sizes depending on theapplication
Limitations include:
Cost
Size of the CMM in a facility
Working volume limited to the size of the CMM bed
What is a Portable CMM?
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What is a Portable CMM?
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Typically 6 or 7 degrees ofarticulation resulting in flexibilitywithin a volume
Quick and simple to use
Can work in a wide range ofenvironments
Accurate up to 0.0125 millimeters
Wireless (Wi-fi/Bluetooth) capabilities
Various compatible probe sizes, includingRenishaw Touch Probes
What is a Portable CMM?
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What is a Portable CMM?
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Available in multiple lengths/ranges (from 4feet to 300 feet)
Multiple mounting options
Compatible with leading inspection softwarepackages such as Polyworks, Spatial Analyzer,Metrologic and Geomagic
Benefits include:
Efficient compared to hand tools = lessmeasurement time
Portable device = less space
Check defects faster = less re-working
Increased productivity and efficiency = less wasteand less downtime
Practical Applications
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Practical Applications
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling
Rapid Prototyping
Practical Applications
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Practical Applications
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling
Rapid Prototyping
Practical Applications
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Practical Applications
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling
Rapid Prototyping
Practical Applications
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Practical Applications
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling
Rapid Prototyping
Practical Applications
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Practical Applications
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling
Rapid Prototyping
Case Studies: Express Manufacturing
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Case Studies: Express Manufacturing
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Custom, small quantity machine shop in the Aerospace industry
Would remove parts from machine to an off-line inspection station
Moved to on-machine inspection
First project using Lean technique reduced time from 5 weeks to 3 weeks.
Case Studies: Oil States
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Case Studies: Oil States
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Manufactures winches, cranes, and mooring systems for offshore oil drilling
Unable to accurately model very large pieces of equipment using standard hand tools
Portable CMMs now used in incoming and in-process inspection
Reduced inspection time up to 75%
Case Studies: Sun Country
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Case Studies: Sun Country
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Manufacturers of jet engine and airframe components
Were seeing inconsistent measurements with hand tools from one operator to another duringon-line measurement, and extreme delays using off-line CMM
On-line portable CMM installedeliminated variation and expensive off-line CMM costs, andreduced inspection time by 60%
Case Studies: Suzuki
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Case Studies: Suzuki
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Manufactures four-wheel ATV
Originally used stationary, off-line CMM and hand tools, but had troubles with accuracy anddata reporting
Implemented articulating arm on-line CMM to improve consistency, shorter time, and costsavings
QC Tech quoted: I can measure faster, and I dont have to break my back doing it.
Case Studies: BAE Systems
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Case Studies: BAE Systems
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Awarded 155mm Advanced Gun System contract for US Navy destroyers
No solution was available to accurately position the Gun System in 3D spacesystem is 24by 13 and needed 0.002 degrees of accuracy on all angles.
Installed a Laser Tracker systemcollected 5000 positioning points within 30 minutes versususing a theodolite which would take weeks, according to BAE Mfg. Engineering
More Case Studies
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More Case Studies
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Boeing Cable AssembliesCycle reduction 85%
Floor space reduction 65%
Kimberly-ClarkCustomer complaint reduction 50%
Allied Signal
Defect rate reduction 29%WIP reduction 42%
Productivity improvement 32%
Pella CorporationWIP reduction 56%
Order to ship cycle time 60%
Productivity improvement 50%
Capital spending reduction 66%
Zellweger Analytics
First pass yields from 88% to 99.5%
Nacom Corporation
Scrap reduction 92%
Summary
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Summary
Lean Manufacturing and Portable Metrology:Improving Manufacturing Efficiences
Lean Manufacturing is a production process that can help save
time, labor and money by eliminating waste
Lean tools such as 5S (workplace organization), cellularmanufacturing and in-line inspection can help reduce harmfulwaste, thus improving product efficiency
Brainstorm with other departments and evaluate every aspect ofa process with the 5 Whys
Portable CMMs can help streamline both the manufacturing andquality aspect of a product, benefitting both the manufacturer
and the customer
Dont forget: Lean Manufacturing is a continual process. Alwaysstrive for perfection!
Thanks for Attending
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Thanks for Attending
For questions about todays webinar:
Chad CrisostomoE: [email protected]
Find FARO on the web:
Website: faro.com
Facebook: facebook.com/FAROTechnologies
Twitter: twitter.com/FARO_HQ
Blog: farotechnologies.blogspot.com
YouTube: youtube.com/user/FAROTechnologies