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Creating Mixed Model Value Streams
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Table of Contents

Introduction
Questions for Mixed Model
Getting Started
Challenges of the Real Factory
A New Look at These Challenges with Value Stream Mapping
Where Do We Start?
Welcome to EMC Supply Company
Our Visit to EMC Supply
Mixed Model Production Product Families and the Pacemaker
Question 1-Do We Have the Right Product Families?
Product Families: A Closer Look
Developing the Product Family Matrix at EMC
Refining the Product Families
The Current-State Map
Developing a Future State
Question 2-What Is the Takt Time at the Pacemaker?
Takt Time
Question 3-Can the Equipment Support the Takt Time?
Cycle Time
Question 4-What Is the Interval?
Determining the Interval Flow at the Pacemaker
Question 5-What Are the Operator Balance Charts for the Products?
What Time Do We Balance To?
Creating Operator Balance Charts
Balancing Machine Cycles
Identifying the True Pacemaker
Material Presentation
Question 6-How Will We Balance Flow for the Mix?
Balancing Products with High Work Content into the Family
Varying Labor: A Closer Look
Changeovers at the Pacemaker
Question 7-How Will We Create Standard Work for the Mix?
Documenting Standard Work
Visual Method Sheets
Smart Tools and Standard Work Pitch and Scheduling
Question 8-How Will We Create the Pitch at the Pacemaker?
Leveling Using Pitch
The Schedule Box
Creating Pitch at EMC Supply
Inverse Pitch
The Future State
Question 9-How Will We Schedule the Mix at the Pacemaker?
Mix Logic Charts
Creating the Mix Logic Chart at EMC Supply
Leveling the Mix
Loading the Schedule Box
The Future State Customer Demand
Question 10-How Will We Deal with Changes in Customer Demand?
Smoothing Demand with Dynamic Supermarkets
Building to Changing Customer Demand
Determining the Starting Point
The Future State

How Will Upstream Processes Support the Pacemaker?
Offset Sequencing
Sequenced FIFO

Putting It All Together
How Does It All Work?
Running the Future State
What's Next for the Team?
Kevin J. Duggan on Lean

Appendices
Lean Glossary
EMC Supply Data Set

Important Sources

Index

About the Author

Kevin J. Duggan is President of Duggan Associates and Founder of The Institute for Operational Excellence, North Kingstown, Rhode Island. Duggan Associates is an educational and advisory firm that specializes in advanced lean training to create Operational Excellence. Mr. Duggan is an expert in developing and applying advanced lean techniques.

Reviews

Praise for the Bestselling First Edition: Finally, a book that addresses the real world complexity of implementing lean in a mixed model environment! Creating Mixed Model Value Streams is must reading for anyone who is trying to make improvements beyond a basic value stream map. From selecting a product family to scheduling and dealing with customer demand, this book shows you how to implement a lean value stream in a way that everyone will understand. --Glynn Miller, Director, Consumer Centered Enterprise, Whirlpool, June 2004 This excellent how-to guide will help set free those of us who have been handcuffed by complexity in our manufacturing systems. It translates theoretical lean into practical guidance for use in the trenches. --Al Mason, Manager, Process Improvement, Goodrich Corporation, June 2004 We work with companies across all industry sectors enabling them to keep increasing their levels of Lean expertise. One of the issues we see them struggle with time and again is, How do we make product flow when there are a variety of products in the same value stream?" Without any quality books on the topic, it has been no easy task to explain - until now. This book demystifies and simplifies the concept of Flow in complex environments. When you put the book down, you will understand there is a solution to your situation. Your only regret will be - why didn't I have this knowledge sooner. --Larry D. Cott, Lean Advisors Inc., June 2004

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