MIXED MODEL LINE DESIGN: THE STEP-BY-STEP GUIDE TO BUILDING THE PERFECT VALUE STREAM...

THE IN-DEPTH COURSE FOR LEAN INDUSTRIAL ENGINEERING AND MIXED MODEL MANUFACTURING…THE SOURCE OF 80%+ OF THE BENEFITS OF LEAN MANUFACTURING!

MIXED MODEL LINE DESIGN
CERTIFICATE COURSE

Mixed Model Line Design is the step-by-step methodology for designing high-mix production lines or value streams. The result is a production line that can manufacture a large number of different products and options, with high efficiency and quality.

The tools of Mixed Model Line Design allow the design of lines that can handle inevitable changes in mix and volume, without degrading throughput or productivity. And they avoid the need for batching models, and for extensive and costly line changeovers.

COURSE AGENDA

How do you know if the line is performing as expected? Is that slow down normal? Getting educated in Mixed Model line design will enable you to “read” the line so you know how it is performing.

Mixing products has a host of advantages including better lead times, increased flexibility, more efficient use of floor space, and leveled product volumes.

A Process Flow Diagram shows the relationship between your processes and the flow (or sequence) necessary to make one unit of a specific product.

One Process Flow Diagram does not provide enough information to make well-informed decisions on the whole line, so you must find a way to extract applicable information.

Takt Time is the line’s formulated production rate. This rate is calculated and is an important design parameter for the line.

In this lesson we’ll cover some of the difficulties you must overcome to calculate an accurate Takt Time, including how to account for many factors that influence Takt such as changes in Effective Minutes, Rework, Scrap, Options, and Quantity consumed.

Standard work is a foundational element of Lean. In this lesson, we will discuss the benefits of Standard work, how to use Standard Work, and why it is important to use graphics in your Standard Work definitions.

Understand how to use the Resource Calculation Formula, and learn how to interpret and apply the results of your Resource Calculations.

In this lesson, you will learn how to calculate the necessary number of workstations on your line and how to determine the distribution of work between those workstations.

In-Process Kanbans (IPKs) are a necessary component of many mixed model production lines. In this lesson we will introduce the benefits and application of IPKs, as well as the best methods for calculating the optimum number of IPKs between your workstations.

Learn about the six line balancing tools, how to use them, when to use them, and the incredible benefits that come with a well balanced line.

Every line designer has to consider how machine processes will impact his or her line. In this lesson, you will learn about the different types of machines, their strengths and weaknesses, and how to integrate machines with IPKs and the balancing tools.

Every mixed model production line has to deal with changeovers, but you don’t have to allow those changeovers ruin your design. This lesson is all about strategies to minimize, as much as possible, the negative impact of changeovers on your line design.

Before jumping straight into CAD, it is important to first create a conceptual design. In this lesson you will learn why conceptual designs are useful, how to create them, and which inputs go into a conceptual line design.

When is Simulation Modeling necessary? What data goes into a successful model? How do you get that data? And, when the model is completed, how do you analyze those results?

This lesson teaches you the steps that go into creating your Final Layout, as well as the departments that should be involved.

Once you CAD drawing is complete, how do you take that drawing and turn it into a live production line?

WHO PRACTICES MIXED MODEL LINE DESIGN?

This is a partial list of the companies that we have worked with on Mixed Model Manufacturing (MMM) improvement projects, or have trained in MMM in our public and private workshops, including those hosted by Toyota Material Handling.

Advanced Lighting Technology
B/E Aerospace
Baker Hughes
Ball Aerospace
The Boeing Group
Borg Warner
CCX Corporation
CNH Reman
Cummins
Daimler Trucks North America
Emerson Electric
Fender Musical Instruments
Fox Racing Shox
GE
Hayward Industries
Hitachi
IBM
Ingersoll Rand
Jabil
John Deere
The Linde Group
MacLean Power Systems
Mattel

Medtronic
Panduit
Parker Hanifin
Performance Composites
Performance Excellence Pathways
Performance Fibers
Plexus
Polaris
Quality Electrodynamics
RBC / Aircraft Products
Rolls-Royce Corporation
S&C Electric Company
Schutt Sports
Spellman High Voltage
Spirit AeroSystems
Stanley Black & Decker
Stant Corporation
Superior Industries
Thermo King
Toyota
United Performance Metals
US Endoscopy
Volkswagen

VIDEO: INTRODUCTION TO MIXED MODEL MANUFACTURING

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WHO WE ARE

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Leonardo Group Americas was founded by Richard Rahn and Gerard Leone, industry vets with 25+ years of Lean experience. They are the authors of eight books on Lean subjects, including The Complete Guide to Mixed Model Line Design. Since 2011 they have partnered with Toyota Material Handling to present workshops on the subjects of Mixed Model Line Design and Mixed Model Material Management to thousands of Industrial Engineers and Lean Professionals. A sister organization in Munich, Germany provides the same approach to Lean in the European Union.

The Lean Design Studio is the culmination of the tools and the methodologies that these two experts have developed over their decades in industry. The Lean Design Studio combines online versions of our core training courses with a newly developed simulation tool, designed specifically for Mixed Model Manufacturing applications.