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Mixed Model Line Design Roadmap

1 Create Training Plan and Master Plan
13 Tasks
1.1 Identify Target Area
1.2 Complete Self-Assessment
1.3 Estimate Quantifiable Benefits
1.4 Appoint MMLD Team Leadership
1.5 Align Project with Corporate Goals
1.6 Train Mixed Model Work Flow Team
1.7 Define and Document Line Design Guidelines
1.8 Define and Document Line Acceptance Criteria
1.9 Walk and Record the Target Area
1.10 Prepare Value Stream Maps
1.11 Develop Future State VSM
1.12 Document Process Improvement Opportunities
1.13 Create Master Plan
2 Gather Mixed Model Line Design Data
8 Tasks
Confirm Targets
List All Products and Options
Establish Volumes and Mix
Document Processes
List Production Resources
Create Process Flow Diagrams
Create Process Flow Matrix
Define Initial Product Families
3 Develop Standard Work Definitions
11 Tasks
Identify Target Process
Assign SWD Documentation Team
Establish SWD Form
Video Process (Optional)
Document Work Steps
Standardize Work Steps
Establish Quality Criteria
Record Work Step Times
Document Supplies and Parts
Document Tools and Equipment
Conduct Staff Review
4 Calculate Resources
6 Tasks
4.2 Modify Process Flow Matrix
4.3 Calculate Effective Work Minutes
4.4 Calculate Takt Time
4.5 Add Standard Times
4.6 Calculate Resources
4.7 Refine Calculations
5 Workstation Definition
12 Tasks
5.1 Identify Parallel Processes
5.2 Identify Sequencial Processes
5.3 Balance Work Content By Product
5.4 Design Workstations
5.5 Create Graphic Work Instructions
5.6 Assess Workstation Capability
5.7 Flag All Stations Over Time Target
5.8 Eliminate NVA Steps
5.9 Relocate Work
5.10 Add Resources
5.11 Set In Process Kanbans
5.12 Develop Initial Sequencing Rules
6 Conceptual Layout
8 Tasks
6.1 Collect Layout Data and Prepare Space
6.2 Identify Path of Highest Volume
6.3 Lay Out Processes
6.4 Document Resource Details
6.5 Design Material Presentation
6.6 Document Decisions
6.7 Set Signoff
6.8 Define and Document Line Performance Criteria
7 Design Validation With Simulation
8 Tasks
7.1 Assess Process Variability
7.2 Determine Simulation Software
7.3 Build Simulation Model
7.4 Validate Model
7.5 Test Mix and Volume Scenarios
7.6 Conduct Simulation Model Review
7.7 Invite Outside Review
7.8 Document Findings
8 CAD Layout
7 Tasks
8.1 Gather Data for CAD Layout
8.2 Acquire Baseline Floorplan
8.3 Assign CAD Operator
8.4 First Pass Layout
8.5 Detailed Layout
8.6 Gemba Walk
8.7 Documentation and Final CAD Layout
9 Deployment Plan
8 Tasks
9.1 Define Other Assets
9.2 Identify Capital Expense Items
9.3 Create Physical Improvement Checklist
9.4 Define Major Milestones
9.5 Create Time-Phased Implementation Plan
9.6 Assign Resources
9.7 Obtain Final Capital Expense Approval
9.8 Fix Launch Date
10 Training
7 Tasks
10.1 Gather Detailed Line Balance Data
10.2 Create Skill List by Workstation
10.3 Assess Skills Available
10.4 Conduct Flow Manufacturing Basics Training
10.5 Train in Workstation Definition
10.6 Certify Line Live Operators
10.7 Set Certification Parameters
11 Line Live
9 Tasks
11.1 Conduct Line Live Assessment
11.2 Determine Launch Strategy
11.3 Create Daily Performance Display Boards
11.4 Audit All Parts and Materials
11.5 Communicate Line Live Plan
11.6 Install Visual Factory Aids
11.7 Begin Pilot Run
11.8 Appoint Quick Response Team
11.9 Line Live Celebration
12 Line Performance Audit
8 Tasks
12.1 Define Line Certification Process
12.2 Conduct Line Audit
12.3 Create Audit Task Force
12.4 Compare Line Performance to Initial Estimates
12.5 Create Gap Analysis
12.6 Audit Operator Behavior
12.7 ReTake Assessment Questionnaire
12.8 Conduct Final Certification Audit
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Create Process Flow Diagrams

Mixed Model Line Design Roadmap 2 Gather Mixed Model Line Design Data Create Process Flow Diagrams

Draw the relationship of processes to build a single unit of product in an individual chart. This is the definition of a Process Flow Diagram and one must be drawn for each product on the product list created earlier. It is very likely that a single PFD will reflect the process relationships for more than one product.

Create Process Flow Matrix

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