MTM & Lean Application Case Studies

MTM and Lean Case study

MTM and Lean Case Study

By Guillaume Lachèvre

MTM Productivity Group France

[email protected]


Introduction

• Lean and MTM are world wide use to reach the maximum efficiency of a production

• Lean reach a high level of productivity based on a global analysis of thee process

• MTM reach a high level productivity on a local analysis of the process

• Combination of both concepts bring to High level of efficiency


Presentation

• Case study on a batch

production of outdoor cooking

appliances

• Highly seasonable products

(70% of the production in 4

months)

• Production on a “old fashion line”

• 25 different references on the

line, 3 major family: gas, electric,

combo (electric and gas)

• AS IS situation with a stop and

go strait line, 4 operators.


AS IS

Balancing made by function

• WS1: frame assembly

• WS2: electrical and gas assembly

• WS3: normative control

• WS4: accessories and packing

produce 50 parts / days = 7,5 part/hours


AS IS

Small

Components

for WS 1

Small

Components

for WS 2

Small

Components

for WS 3

Small

Components

for WS 4

Change of components batch 1 per shift

Stock

S

t

o

c

k

S

t

o

c

k

S

t

o

c

k

Components

for WS 1 Components

for WS 2

Components

for WS 3 Components

for WS 4


AS IS

• Flexibility:

1 reference per day

No place for more or less operators

• Efficiency:

No time measurement

Operators to defines production target

First operator wait until last operator finished the last product of the day

• Reactivity:

Setup time = 2h made 1 time per day

Production to stock

No database to react quickly to a new product

NEED of a complete reorganization of the line


AS IS

• Reduce Stocks

• Increase flexibility (customer

oriented production)

• measure efficiency

• Improve production reactivity


Project Team

• Project Coordination: G. Lachèvre (external)

• Project team composition:

• Lean Group: • 1 Industrial engineer (internal)

• 1 logistic engineer (internal

• MTM Group • 1Industrial engineer ((internal)

• 1 consultant from thee MTM Productivity Group

• Sponsored by Top Management with support of all

services…

• Use of MTM and line balancing software Equinoxe


Main Tasks

• Setting up a milk-run

• Modification of Layout (U shape)

• Setting up a batch size

• Use of all other Lean tools (TPM, 5S, Kanban, …)

• To furnish Time database for all aspect of

production

• To decide best practice for assembly

• to implement a efficiency measurement

• To implement a reactive task force to improve

efficiency


MTM Tools Association MTM Française

42 Ave Montaigne 75008 Paris Tél : + 33 (0) 1 53 6744 75 Email : [email protected]

SOL Standard Operations

Logistics

L’utilisation de ces valeurs de tables sans une formation approfondie en MTM-UAS et MTM Logistique, peut conduire a des résultats erronés.

Tracteur électrique 4LT TMU

Conduire

Intérieur Avec remorque (/ m) EFIM 13

Sans remorque (/ m) EFIO 10

Extérieur Avec remorque (/ m) EFAM 13

Sans remorque (/ m) EFAO 7

tourner 90° Avec remorque (/ m) EFKM 92

Sans remorque (/ m) EFKO 38 Arrêt

(décélération et accélération)

Avec remorque (/ m) EFVM 56

Sans remorque (/ m) EFVO 30

Accrocher Avec Alignement EANM 368

Sans alignement EANO 258

Décrocher Avec Alignement EABM 285

Sans alignement EABO 182

Addition Remorque supplémentaire EAZZ 200

Tire-Palette 5LT TMU

Tracter

Tracter par m ≤ 500 kg HFFA 30

> 500 kg HFFB 35

Tourner 90° ≤ 500 kg HFKA 15

> 500 kg HFKB 19

Arrêt

(décélération et accélération)

≤ 500 kg HFVA 80

> 500 kg HFVB 150

Enlever palette

Avec Alignement ≤ 500 kg HAMA 520

> 500 kg HAMB 615

Sans Alignement ≤ 500 kg HAOA 350

> 500 kg HAOB 415

Poser palette

Avec Alignement ≤ 500 kg HPMA 295

> 500 kg HPMB 310

Sans Alignement ≤ 500 kg HPOA 125

> 500 kg HPOB 130

Alignement additionnel ≤ 500 kg HRZA 125

> 500 kg HRZB 190

Chariot manuel 4LT TMU

Pousser par m

≤ 50 kg WFA 25

≤ 100 kg WFB 28

≤ 200 kg WFC 30

> 200 kg WFD 35

Tourner 90°

≤ 50 kg WKA 15

≤ 100 kg WKB 11

≤ 200 kg WKC 8

> 200 kg WKD 8

Arrêt (décélération et accélération)

≤ 50 kg WVA 35

≤ 100 kg WVB 45

≤ 200 kg WVC 80

> 200 kg WVD 105

Alignement additionnel

≤ 50 kg WRA 80

≤ 100 kg WRB 105

≤ 200 kg WRC 160

> 200 kg WRD 215

AA/JG © MTM-Institut

Copyright déposé! Reproduction interdite!

• Use of MTM Standard

Operation logistic

• Defining time for a

Run definition of a

production Batch size

• Milk run used on other

line of the plant

• Coordination with

supplier to reduce

manipulation


MTM tools

motion length

in cm ≤ 20

> 20

to

≤ 50

> 50

to

≤ 80

distance range 1 2 3

Get and Place Code 1 2 3

TMU

≤1

daN

easy

approx. AA 20 35 50

loose AB 30 45 60

tight AC 40 55 70

difficult

approx. AD 20 45 60

loose AE 30 55 70

tight AF 40 65 80

handful approx. AG 40 65 80

> 1 daN

to

≤ 8 daN

approx. AH 25 45 55

loose AJ 40 65 75

tight AK 50 75 85

> 8 daN

to

≤ 22 daN

approx. AL 80 105 115

loose AM 95 120 130

tight AN 120 145 160

Place Code 1 2 3

TMU

approx. PA 10 20 25

loose PB 20 30 35

tight PC 30 40 45

motion length

in cm ≤ 20

> 20

to

≤ 50

> 50

to

≤ 80

distance range 1 2 3

Handle Aid Code 1 2 3

TMU

approximate HA 25 45 65

loose HB 40 60 75

tight HC 50 70 85

Operate Code 1 2 3

simple BA 10 25 40

compound BB 30 45 60

Motion Cycles Code 1 2 3

one motion ZA 5 15 20

motion sequence ZB 10 30 40

shift and one motion ZC 30 45 55

tighten or loosen ZD 20

Body Motions Code TMU

walk / m KA 25

bend, stoop, kneel (incl.

arise) KB 60

sit and stand KC 110

Visual Inspection VA 15

• Use of MTM-UAS to

build operation

Standard Time

• Creation of Data

block per function

• Creation of products

with these bocks

• Use of software EQUINOXE


Exemple Measurement

Small

Components

for WS 1

Components

for WS 1

2 m

Components for WS 1

Displacement of 2x2 meters 4 times per

cycles

MTM Calculate that the gain is

KA x 2 x2 x4 = 25 TMU x 16 = 400 TMU

= 14 s per cycles = 10% of cycle time

No Displacement


Advantage

• MTM Bring measurement

to operation to determine

gains and best solution

for improvements

• Used to calculate Return

On Invest

• Creation of a standard

database for new

products


Assembly Line

• U line

• Products on trolley

• Operators pushing trolley from 1 zone to the other

• Full cycle include: Assembly, wiring, electrical control and packing

• operator working in 1 or several zone (depending on balancing)

• Impossible for an operator to perform a full cycle (competences and quality)

• Nominal balancing: 4 operators

• Component feeding by milk run; exact number for the batch


Database creation

• 1 dedicated software: A modification of an operation affect all products on which it is made

• For each operation: zone, VA or NVA, rest allowance and MTM-UAS standard time

• Creation of the reference product, depending on the forecasted production mixt

• Balancing of the high runner

• Balancing of the remaining operation for the next product (by order of importance in the production

mixt)

a common operation will always be performed at the same place

Standard Operations

MTM UAS analysis Products

Cross table

operation per product

Balancing

5 op

Balancing

AS IS

Balancing

3 op

Balancing

4 op

Production mixt


To BE


Balancing per function

10,37

74%

Cadence 12,8 Cadence 9,7 Cadence 12,7 Cadence 10,0

Perfomance 80% Perfomance 81% Perfomance 88% Perfomance 71%

weight 7,44% weight 5,17% weight 2,09% weight 54,62%




Cadence

Perfomance

BALANCING AS IS

Produit de REF

65,78%61,69%

100,00%

69,50%

0,00%

100,00%

1 2 3 4

GXX3T

57,33%66,22%

97,62% 100,00%

0,00%

100,00%

1 2 3 4

GXX3M

60,03% 62,03%

100,00% 95,94%

0,00%

100,00%

1 2 3 4

GXX4T

68,71%83,63%

100,00% 99,83%

0,00%

100,00%

1 2 3 4

GXX4M

71,08% 77,09%

100,00% 95,32%

0,00%

100,00%

1 2 3 4

XTX4T

65,06%57,56%

100,00%

62,39%

0,00%

100,00%

1 2 3 4

XTX4M

71,19%61,55%

100,00%

58,92%

0,00%

100,00%

1 2 3 4

XXF3T

74,78% 80,88%100,00%

68,62%

0,00%

100,00%

1 2 3 4

XXF3M

69,36% 70,84%

100,00%

65,34%

0,00%

100,00%

1 2 3 4


Balancing principle

• MTM determine times per operation

• Creation of equivalent workload for each

operators

• Creation of addresses of component on he

line

balancing is made on a time database (not

per function)

Balancing made on reference product

(weighted average of production)


Balancing 4 op

13,94

99%







Cadence

Perfomance

BALANCING 4 OPERATORS

Produit de REF

98,94% 100,00% 99,73% 99,25%

0,00%

100,00%

1 2 3 4

GXX3T

85,71% 92,75% 100,00% 94,45%

0,00%

100,00%

1 2 3 4

GXX3M

95,42% 94,87% 100,00% 92,43%

0,00%

100,00%

1 2 3 4

GXX4T

87,47%100,00%

90,91% 83,40%

0,00%

100,00%

1 2 3 4

GXX4M

96,18% 100,00%88,88% 81,54%

0,00%

100,00%

1 2 3 4

XTX4T95,30% 97,96% 97,90% 100,00%

0,00%

100,00%

1 2 3 4

XTX4M100,00% 99,03% 96,81% 91,36%

0,00%

100,00%

1 2 3 4

XXF3T100,00% 94,99%

84,26% 91,12%

0,00%

100,00%

1 2 3 4

XXF3M100,00%

85,83% 84,25% 89,38%

0,00%

100,00%

1 2 3 4


Results for the

average product

per function 4 OP 3 OP 5 OP

performance 74,1% 99,6% 98,9% 95,7%

nb of

operator4 4 3 5

Balancing

loses (s)-357 -5 -11 -46

Cadence

(P/H)10,38 13,98 10,42 16,80

Productivity 34,68% 33,84% 29,51%

All Info are available for all products in a bijective way

production objectives Nb of operators requested

Nb of operator available (absenteeism) production objectives

Based on MTM standard time


Non Quality

Waste operation

Frequencial

NVA

Cyclic

NVA

Operator efficiency

Ad

ded

Valu

e

Co

ncep

tio

n T

ime

Design

coefficient

Efficiency coefficient

KE

Support functions

Tem

ps a

ttri

bu

é a

u s

ecte

ur

Global

organisation

breakdown

Spend t

ime

Production

datas

MTM

Paid hollidays allowance

Accountancy datas

Paid

tim

e

Setting an efficiency

measurement


Setting an efficiency

measurement Dates: 24/02/2013 KE 86,11%

Line: E target KE 80%

products GXXF3456m

70

65

60

55

50

45

40

35

30

25

20

15

10

5

1 2 3 4 5 6 7 8 TIME

h expected made

1 10 7

2 20 24

3 25 25

4 35 27

5 40 29

6 50 44

7 60 58

8 72 62

Balancing : 4 op

Production report sheet

Front panel issue not punched at the back

support from another operator switching to 4 op

balancing

gas test machine default

Team Leader: XXXXXXXX

X

X XX X

X

XX


Efficiency measurement


Results

• Increasing of efficiency from 65% to 87%

with measurement we can improve

• Support service can categories the loses and check the

nb of product lost

better reactivity of services

• Choice to get:

• 3 operators for low season

• 5 operators for High season

Better flexibility

Most important Operators are now asking for

generalization of the system


• With MTM we can now measure any kind

of product from the line…

• Even the most sophisticated one


Guillaume LACHÈVRE

MTM Instructeur

Email: [email protected]

Mobile: +33 (0)6 80 74 44 34

Engineering

MTM & Lean Application Case Studies