MD Faro Webinar

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiencies
Presented By Chad Crisostomo Technical Product Manager (FaroArm)
FARO Technologies
09/18/2012
Purpose
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
Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences
Agenda
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
What is Lean Manufacturing?
Lean is not simply a toolbox, but a total perspective.

-The Gold Mine, by Michael and Freddy Balle
What is Lean Manufacturing?
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!
The Guiding Principles of Lean
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 can be eliminated?
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 it and when they desire it?
5.
Seek Perfection!
Now that weve identified value and produced a value product for our customer, is there room for improvement? Can the process evolve? Can we eliminate more waste?
Of course!!!
"For improvement to flourish it must be carefully cultivated in a rich soil bed (a receptive organization), given constant attention (sustained leadership), assured the right amounts of light (training and support) and water (measurement and data) and protected from damaging*.
-Stephen Shortell, Ph.D., Organizational Behavior Professor
*What kind of damage is Dr. Shortell referring to?
The Seven Deadly Wastes
The most dangerous kind of waste is the waste we do not recognize.

-Shigeo Shingo, Toyota
The Seven Deadly Wastes (TIM WOOD)
The Seven Deadly Wastes are activities that have been identified as non-value adding events or processes that hinder profitability in a company. They include:
The Seven Deadly Wastes (TIM WOOD!)
Transportation Unnecessary movement of valued goods from one process to the next
Inventories Excess product (raw material or finished goods) waiting to be processed
Motion unnecessary movement or transportation of people and equipment due to an inefficient layout or process
The Seven Deadly Wastes (TIM WOOD!)
Waiting time spent waiting idly for a process or task to finish

Over processing Using more energy than is required to produce a product (poor tool design) Overproduction Excessive operations necessary to produce a product, making something before it is truly needed Defects/mistakes time spent repairing or reworking material that could cause customer dissatisfaction
Now that we know what kind of activities to avoid, what are some of the lean tools at our disposal?
Lean Tool Example: 5S (Workplace Organization)
What is 5S? A series of activities for organizing a work space for effectiveness and eliminating wastes that contribute to errors, defects and injuries
Sort
The stages are: 1. Sort: Clearly distinguishing what is necessary and disposing of the unnecessary Straighten: Organizing the necessary items so that they can be used and returned easily
Standardize
Sustain!
Straighten
2.
Shine
Lean Tool Example: 5S (Workplace Organization)
3.
Shine: Cleaning floors, equipment, and furniture in all areas of the workplace Standardize: Maintaining and improving the standards of the first 3 Ss Standardize
Sort
4.
5.
Sustain: Achieving the discipline of properly maintaining the correct 5S procedures and striving for continual improvement
Sustain!
Straighten
Shine
Lean Tool Example: 5S (Workplace Organization) Examples
Before
After
Before
After
Before
After
Lean Tool Example: 5S (Workplace Organization) More of Examples of
Lean Tool Example: 5S (Workplace Organization) More of Examples of
Lean Tool Examples: Kaizen
What is Kaizen? Focuses on eliminating waste, improving productivity and achieving sustaining improvement in processes of an organization Relies on analytical techniques (such as the 5 Whys) to identify opportunities to eliminate waste in a specific process Often considered to be the building block of all lean production methods
Shewhart Cycle One of the major components of Kaizen is the Shewhart Cycle.
The 4 stages are:
Plan Create a plan for change, defining the steps you need to take to make the change
Do Carry out the plan in a test environment, under controlled conditions

Shewhart Cycle
Shewhart Cycle
Check Examine the results of the trial. Verify the process improved. If not, try again!
Act Implement the changes on a broader scale and update the standard operating procedures.
Shewhart Cycle
Key Elements of Kaizen include: Quality Effort Employee participation Communication Willingness to change
Lean Tool Examples: Cellular Manufacturing
What is Cellular Manufacturing?
Arranging workstations in a sequence that promotes a smooth flow of materials through the production process with minimal wait or transport Helps to eliminate overproduction, reduce defects and save floor space Proven to be more flexible and responsive than the traditional massproduction line
Shopfloor Flow (before CM)
4 5
Queue Bench 1
Shopfloor Flow (After CM)
6
U-Shaped Solution
5
Parallel Solution
Lean Tool Examples: In-line Inspections
What are In-line Inspections?
Removes the need for separate testing and inspection labs
Allow workers to perform inspections directly on the line (in-process)
Decreases rework time and eliminates scrap

Typical Batch Manufacturing (Before Lean):
Typical Batch Manufacturing and Inspection
Opn 1 Queue Opn 1
Opn 2 Queue Opn 2
Opn 3 Queue Opn 3
Opn 4 Queue Opn 4
Inspect Finished Goods Inspect
Rework Area
Test and Inspection Lab

Typical Batch Manufacturing (Before Lean):
But What Happens if There is a Failure at Final Inspection?
Opn 1 Queue Opn 1
Opn 2 Queue Opn 2
Opn 3 Queue Opn 3
Opn 4 Queue Opn 4
Rework Area
Batch Manufacturing (After Lean):
LEAN Manufacturing and Inspection
Opn 1
Opn 2
Opn 3
Opn 4 Finished Goods Opn 4
In-Line Inspection = Opn 1 Opn 2 Opn 3
Batch Manufacturing (After Lean):
But What Happens if There is a Failure Anywhere?
Opn 1
Opn 2
Opn 3

But What Happens if There is a Failure at Final Inspection?
Opn 1 Queue Opn 1
Opn 2 Queue Opn 2
Opn 3 Queue Opn 3
Opn 4 Queue Opn 4
Rework Area
But What Happens if There is a Failure Anywhere?
Opn 1
Opn 2
Opn 3
So how do portable CMMs fit into all of this?

What is a Coordinate Measuring Machine (CMM)?
Device for measuring physical geometries of a part in 3 dimensions
Accurate up to one-millionth of a meter

Various sizes depending on the application
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?
Typically 6 or 7 degrees of articulation resulting in flexibility within a volume
Quick and simple to use

Can work in a wide range of environments
Accurate up to 0.0125 millimeters Wireless (Wi-fi/Bluetooth) capabilities Various compatible probe sizes, including Renishaw Touch Probes
What is a Portable CMM?
Available in multiple lengths/ranges (from 4 feet to 300 feet) Multiple mounting options
Compatible with leading inspection software packages such as Polyworks, Spatial Analyzer, Metrologic and Geomagic
Benefits include:
Efficient compared to hand tools = less measurement time

Portable device = less space Check defects faster = less re-working Increased productivity and efficiency = less waste and less downtime
Practical Applications
Reverse Engineering
CAD to Part Analysis
Alignments
3D Modeling Rapid Prototyping
Reverse Engineering
Alignments
Reverse Engineering
Alignments
Reverse Engineering
Alignments
Reverse Engineering
Alignments
Case Studies: Express Manufacturing

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

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

Manufacturers of jet engine and airframe components Were seeing inconsistent measurements with hand tools from one operator to another during on-line measurement, and extreme delays using off-line CMM On-line portable CMM installed eliminated variation and expensive off-line CMM costs, and reduced inspection time by 60%
Case Studies: Suzuki

Manufactures four-wheel ATV Originally used stationary, off-line CMM and hand tools, but had troubles with accuracy and data reporting Implemented articulating arm on-line CMM to improve consistency, shorter time, and cost savings
QC Tech quoted: I can measure faster, and I dont have to break my back doing it.
Case Studies: BAE Systems

Awarded 155mm Advanced Gun System contract for US Navy destroyers No solution was available to accurately position the Gun System in 3D space system is 24 by 13 and needed 0.002 degrees of accuracy on all angles. Installed a Laser Tracker system collected 5000 positioning points within 30 minutes versus using a theodolite which would take weeks, according to BAE Mfg. Engineering
More Case Studies
Boeing Cable Assemblies

Cycle reduction Floor space reduction 85% 65%
Pella Corporation
WIP reduction Order to ship cycle time Productivity improvement Capital spending reduction 56% 60% 50% 66%
Kimberly-Clark
Customer complaint reduction 50%
Zellweger Analytics
First pass yields from 88% to 99.5%
Allied Signal
Defect rate reduction WIP reduction Productivity improvement 29% 42% 32%
Nacom Corporation
Scrap reduction 92%
Summary
Lean Manufacturing is a production process that can help save time, labor and money by eliminating waste Lean tools such as 5S (workplace organization), cellular manufacturing and in-line inspection can help reduce harmful waste, thus improving product efficiency Brainstorm with other departments and evaluate every aspect of a process with the 5 Whys
Portable CMMs can help streamline both the manufacturing and quality aspect of a product, benefitting both the manufacturer and the customer Dont forget: Lean Manufacturing is a continual process. Always strive for perfection!
Thanks for Attending
For questions about todays webinar: Chad Crisostomo E: chad.crisostomo@faro.com
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
Visit www.faro.com for more

MD Faro Webinar

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Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiencies

Presented By Chad Crisostomo Technical Product Manager (FaroArm)

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

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

What is Lean Manufacturing?

Lean is not simply a toolbox, but a total perspective.

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

What is Lean Manufacturing?

In other words, making more with LESS!

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Guiding Principles of Lean

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Guiding Principles of Lean

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Guiding Principles of Lean

The Guiding Principles of Lean

-Stephen Shortell, Ph.D., Organizational Behavior Professor

*What kind of damage is Dr. Shortell referring to?

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Seven Deadly Wastes

The most dangerous kind of waste is the waste we do not recognize.

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Seven Deadly Wastes (TIM WOOD)

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Seven Deadly Wastes (TIM WOOD!)

Inventories Excess product (raw material or finished goods) waiting to be processed

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

The Seven Deadly Wastes (TIM WOOD!)

Waiting time spent waiting idly for a process or task to finish

Lean Tool Example: 5S (Workplace Organization)

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Example: 5S (Workplace Organization)

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Example: 5S (Workplace Organization) Examples

Lean Tool Example: 5S (Workplace Organization) Examples

Lean Tool Example: 5S (Workplace Organization) Examples

Lean Tool Example: 5S (Workplace Organization) More of Examples of

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Example: 5S (Workplace Organization) More of Examples of

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Kaizen

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Kaizen

The 4 stages are:

Do Carry out the plan in a test environment, under controlled conditions

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Kaizen

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Kaizen

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Cellular Manufacturing

What is Cellular Manufacturing?

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Cellular Manufacturing

Shopfloor Flow (before CM)

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences

Lean Tool Examples: Cellular Manufacturing

Shopfloor Flow (After CM)

Lean Manufacturing and Portable Metrology: Improving Manufacturing Efficiences