Table Of ContentWorking with M achines
The Nuts and Bolts of
Lean Operations with Jidoka
by Michel Baudin
Boca Raton London New York
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ISBN-13: 978-1-56327-329-2 (hbk)
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Library of Congress Cataloguing-in-Publication Data
Baudin, Michel.
Working with machines : the nuts and bolts of lean operations
with jidoka / by Michel Baudin.
p.cm.
ISBN-13: 978-1-56327-329-2 (alk. paper)
I. Manufacturing processes. 2. Production planning.
3. Machinery in the workplace. I. Title.
TS183.B4325 2007
658.5--dc22
2007006607
ii Working with Machines
Acknowledgements
This book is the distillation of many projects, and I would like to acknowl
edge the contributions...
Kei Abe, Kevin Hop
Jim Ayers, Crispin Vincenti-Brown
Dale Bayley, Tom Berghan
Hormoz Moghare
Pierre Choussat
Christian Thomas
Bob Shroer
Charles Parks
Hormoz Mogharei
Shahrukh Irani
Shunji Yagyu
Jose Ignacio Erausquin
Asaf Degani
Working with Machines iii
Contents
Introduction.........................................................................................................1
Jidoka = Working with Machines............................................... 1
Working with machines and competitiveness...................................................3
Inside the book................................................................................................5
PART I Human—Machine interfaces.............................................9
CHAPTER 1 Using machine controls...........................................................11
Performing steps on machines.......................................................................12
Unloading and loading...................................................................................12
Pressing the right button................................................................................14
Monitoring and exception handling...............................................................17
Usability engineering principles......................................................................21
CHAPTER 2 Performing operations on machines.......................................35
Performing operations...................................................................................36
Sequencing constraints..................................................................................37
Natural mappings..........................................................................................38
From process-centered to result-centered interfaces......................................40
Working with Machines v
CHAPTER 3 Understanding the process.....................................................51
Machines used at work versus everyday life...................................................52
Categories of machine processes...................................................................53
How much do the operators need to know?.................................................54
The example of sputtering.............................................................................56
How operators learn......................................................................................59
CHAPTER 4 Programming machines..........................................................63
Impact of machine programmability..............................................................64
Common features of programmable controllers............................................64
Impact of programmability on shop floor....................................................71
Characteristics of machine programs.............................................................76
Who should program machines?............................................ 79
Process programs as tangible assets...............................................................81
PA RT II Machine cells.........................................................................85
CHAPTER 5 Cellular manufacturing with machines.....................................87
Lean manufacturing cells with machines........................................................88
Examples of machine cells............................................................................88
Defining a lean manufacturing cell.................................................................95
Issues with machine cells...............................................................................96
Alternative meanings of the word “cell”......................................................103
The value of cells.........................................................................................104
CHAPTER 6 Design and implementation of a machine cell.......................107
About cell design and implementation.........................................................108
Project planning and project phases.............................................................108
Analysis and design......................................................................................114
Equipment installation.................................................................................124
Cell startup and finishing.............................................................................127
CHAPTER 7 From operator job design to task assignment........................133
Operator job design.....................................................................................134
Related charts...............................................................................................142
Daily task assignments.................................................................................148
vi Working with Machines
CHAPTER 8 Cell automation and chaku-chaku line.....................................155
What is a chaku-chaku line?...........................................................................156
Detailed features of chaku-chaku lines...........................................................158
Multiple cells in one big room......................................................................167
Operators in chaku-chaku lines......................................................................169
Chaku-chaku line implementation..................................................................170
CHAPTER 9 Grouping cells into focused factories...................................173
Cells versus focused factories.......................................................................174
A failed cellularization example....................................................................174
The better way.............................................................................................177
A general approach......................................................................................180
PART III Common services and monuments................................185
CHAPTER 10 Working with monuments....................................................187
What is a monument?..................................................................................188
What is wrong with monuments?.................................................................191
What to do about monuments.....................................................................192
Examples of monuments.............................................................................200
CHAPTER 11 Setup time reduction............................................................215
Setup time reduction, monuments, and flexible lines...................................216
Setup times for individual machines versus lines.........................................216
SMED.........................................................................................................220
Setup time reduction management...............................................................222
Outline of a setup time reduction project....................................................225
Changeover time analysis of a machine........................................................227
General principles for external setup tasks..................................................237
General principles for externalizing internal setup tasks..............................238
General principles for improving internal setup tasks...................................239
PART IV Automation.......................................................................243
CHAPTER 12 The lean approach to automation.........................................245
Is lean manufacturing anti-automation?........................................................246
Jidoka, autonomation, and automation.........................................................246
Working with Machines vii
The seven steps of automation for machining.............................................250
Underlying principles...................................................................................253
CHAPTER 13 Improving legacy automated systems...................................257
What are legacy systems?.............................................................................258
Legacy automated systems in machining......................................................258
Increasing availability...................................................................................261
Routine operations.......................................................................................263
Starting the machine....................................................................................268
Periodic actions...........................................................................................268
PA RT V Machine maintenance.........................................................271
CHAPTER 14 Machine and facilities maintenance......................................273
About maintenance......................................................................................274
The economics of maintenance...................................................................275
Participants in the maintenance business.....................................................277
Balance between planned and unplanned activities.......................................281
Preventive maintenance productivity...........................................................283
Failures and microstoppages................................................................ 284
CHAPTER 15 Improving maintenance................................................. 287
Strategies for maintenance improvement.....................................................288
Reliability-centered maintenance (RCM)......................................................288
Total productive maintenance (TPM)...........................................................292
Maintenance organization............................................................................304
CHAPTER 16 Maintenance information systems........................................309
Computer systems for maintenance.............................................................310
Diagnosis and failure analysis.......................................................................314
Administration, documentation, and paperwork..........................................317
CHAPTER 17 Overall Equipment Effectiveness (OEE).............................323
Is faster better?............................................................................................324
OEE as a machine performance indicator....................................................325
OEE calculations.........................................................................................328
OEE analysis and machine performance improvement................................331
viii Working with Machines
Appropriate and inappropriate use of OEE to improve machine
performance................................................................................................337
Where to go from here?..................................................................................339
Bibliography....................................................................................................343
Books about machining................................................................................343
Books on usability engineering.....................................................................344
Industrial engineering..................................................................................345
Operator job design in cells.........................................................................345
Chaku-chaku lines.........................................................................................345
Focused factories.........................................................................................345
Setup time reduction............................................. 346
Automation..................................................................................................346
Maintenance................................................................................................347
Index..............................................................................................................349
Working with Machines ix
