Value Creation Through
Integration Workshop
A Framework for Integration
from the Manufacturing
Perspective
January 30, 2002
Presented by:
Tom Shields
MIT
Lean
Aerospace
Initiative
Contents
Industrial product maturity impact on manufacturing
What is manufacturing system design
The manufacturing system design framework
2 MS Shields - 1/30/02 © 2002 Massachusetts Institute of Technology
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Lean
Aerospace
Initiative
Post Dominant Design
Industrial Role
Product differentiation harder to achieve
Product performance enhancements best
satisfied by incremental improvements
Acquisition and life cycle costs predominate
Insertion of process technologies has highest
leverage
Use
Use Manufacturing
Manufacturing for
for Competitive
Competitive
Advantage
Advantage
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Lean
Aerospace
Initiative
How can Manufacturing be Used
for Competitive Advantage?
Product design alone is less of a
discriminating factor for competitive
success therefore …
Design efforts should ensure producibility
Manufacturing inputs should carry more weight
Process technology development yields
most benefits
Continual introduction of new processing
capabilities
Organizational elements to champion process
developments
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Lean
Aerospace
Initiative
Elements for a Manufacturing
System Design Framework
A holistic view of manufacturing system design environment
Visual depiction of “design beyond factory floor” ideas
Manufacturing as part of the product strategy
Manufacturing system design is strategy driven, not product
design driven
Combines multiple useful tools
Provides insights into order and interactions
Not prescriptive
Can lead to innovative & new manufacturing system designs
Shows the unending design cycle -- Continuous Improvement
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Lean
Aerospace
Initiative
Manufacturing System Design
1. Manufacturing system “infrastructure” design
Manufacturing strategy
Operating policy
Partnerships (suppliers)
Manufacturing
Strategy Tools
Organization structure details
2. Manufacturing system “structure” design
Buildings, location, capacity
Machine selection
Layout
Manufacturing
System Design
Tools
WIP
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Stakeholders
Society
Suppliers Customers
Corporate Level
Employees Stockholders
Mgmt
Govt.
Design
Manufacturing System
(Corporate Strategy)
[Seek approval]
[Interpret]
Business Unit (Business Strategy)
Product Strategy
Product Design
Manufacturing
Marketing
Requirements/Considerations/Constraints
Manufacturing System Design/Selection
`
Implement (pilot)
Optimizing
Evaluate/Validate
Full Rate Production
Modifications
Suppliers
Lean
Aerospace
Initiative
PRODUCT
Product Strategy
PROCESS
Performance
Specifications
Technology
And process
Planning
Recipe, Unit
Process
Product Design
Details, strategy
Product Design
Manufacturing
System, Make/buy
Marketing
Suppliers
Product
Strategy
Marketing
SUPPLY
CHAIN
Suppliers
Product
Architecture, and
Make/buy
Time,
Space, and
Availability
Product
Strategy
Manufacturing
Manufacturing
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Stakeholders
Manufacturing System Design
Corporate Level
[Seek approval]
[Interpret]
Business Unit
Product Strategy
Product Design
Make/Buy
Risk-sharing Partnerships
Manufacturing
DFMA,IPT
3-DCE
Concurrent Engineering
Marketing
Customer Needs
Technical Feasibility
Feasible performance guarantees
Requirements/Considerations/Constraints
- Miltenburg, - 3P, - 2D plots,
- MSDD, - AMSDD - design Kaizen
Manufacturing System Design/Selection
- Analytical Tools,
- Simulation Tools
Implement (pilot)
Fine Tune
Evaluate/Validate
Finalized Product Design
•
•
•
•
Rate Production
Modifications
Suppliers
VSM
Kaizen
Trial & Error
Kaikaku
Stakeholders
Manufacturing System Design
Corporate Level
[Seek approval]
[Interpret]
Business Unit
Product Strategy
Product Design
Make/Buy
Risk-sharing Partnerships
Manufacturing
DFMA, IPT
3-DCE
Concurrent Engineering
Marketing
Customer Needs
Technical Feasibility
Feasible performance guarantees
Requirements/Considerations/Constraints
- Miltenburg, - 3P, - 2D plots,
- MSDD - AMSDD - design Kaizen
Manufacturing System Design/Selection
- Analytical Tools,
- Simulation Tools
Implement (pilot)
Fine Tune
Evaluate/Validate
Finalized Product Design
•
•
•
•
Rate Production
Modifications
Suppliers
VSM
Kaizen
Trial & Error
Kaikaku
Lean
Aerospace
Initiative
High Level Strategy
Tools/Concepts
Focused Factory
Wickham Skinner
Product-Process Matrix
Hayes and Wheelwright
3-DCE
Charlie Fine
Nine Components of Manufacturing
Strategy
Fine and Hax
Manufacturing Strategy Worksheet
Miltenburg
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Lean
Aerospace
Initiative
Manufacturing System Design
Tools
Axiomatic design/MSDD
Cochran
Production Preparation
Process (3P)
2-D manufacturing world
maps
Toyota production system
frameworks
Ohno, Shingo, and Monden
Various analytical
tools/computer simulation
tools
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Lean
Aerospace
Initiative
Conclusions
Manufacturing system design is more than the factory floor
Manufacturing system design is strategy driven
There is no one size fits all general manufacturing system
design methodology
Best results realized by interacting with design, suppliers
and marketing
Manufacturing is a competitive weapon in a maturing
product industry
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