Truck Operating System (TOS) HumanInfrastructure
Customer Demand Rate
p i h s r e d a e L
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
n o i t a n i
m i l E e t s a W
Subsystem: Just In Time Tool
4.4.1. Fixed Takt Time
Description
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4.4.2. Takt Time /Cycle Time Bar Chart
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Benefits
Takt time = (total available time – non working time)/customer demand Ultimate goal: Single takt time links all operations Takt time is stable, does not change with small changes in demand (i.e. monthly production demand is smoothed to allow for consistent daily build) Adapt to short term demand changes by changing working times (dependent on work contract agreements with work council) In continuously moving assembly lines takt time can be visualized with start/stop lines In automated processes takt time is built into set up of machinery or conveyance
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Is a tool for problem solving and Continuous Improvement (i.e. first understand current situation) A bar chart which illustrates each individual process cycle (e.g. for a workgroup) with respect to takt time Bars may be divided by color to indicate value and non-value added work content
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TOS_System_description_direct_090619.ppt
Reduces/eliminates fluctuation in manpower requirements Provides a stable production demand, build rate and predictability in material usage and replenishment. Eliminates over production.
Visual display for both operators and management Waiting time and bottlenecks are easily identified Can be used by supervisors and operators to rebalance the line when takt time changes Improves cooperation between teams and management on efficiency improvement
Truck Operating System (TOS)
Waste Elimination
Human Infrastructure
Subsystem: Continuous Improvement p i h s r e d a e L
s l l o R d n a s k s a T f o y t i r a l C
s s t e d n e r n a n u e t e t s c e r m n u e e c a i r t w v m p t l u S c A o p l o o a v l r l a r a n t I e v G n P n e e k o k e r e D r i o t y a o m z o d W i l W n o n n e i r p a a f v m g a E r S n E O
Standardization
s d o s h t e e r u M d d e c e z o r i P d r d a n d a n a t S
S 5 / s e u q i n h c e T l a u s i V
Quality Focus and Robust Processes and Products n o i t c e r r o C d n a n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P d n a s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
) l a s n u r e c t o x F E r d e n a m l o a t s n u r e C t n I (
Continuous Continuous Continuous Improvement Improvement Improvement
Just in Time
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P w o l F s u o u n i t n o C
e t a R d n a m e D r e m o t s u C
n o i t a n i m i l E e t s a W
Tools We improve Safety, Quality, Delivery, Cost, and Morale and increase profit by continuously eliminating waste and reducing manufacturing lead times. • Extensive employee involvement in all phases of the project • Workshop concepts are driven and installed; in so doing expert-done continuous improvement workshop progresses into staff-done continuous improvement workshop. • All types of waste treated viewed harshly and quickly eliminated • Takes place at all levels of the organization Tools listed in this model are: • Plan, Do, Check, Act (PDCA) • 7 Wastes • 5 Why`s (5 W`s) • Process Map • staff-done Continuous Improvement Workshop • expert-done Continuous Improvement Workshop • Engineering Change Control • Practice Sharing Benchmark • Simultaneous Engineering
TOS_System_description_direct_090619.ppt
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
Subsystem: Continuous Improvement Tool
5.1.1. PDCA
Description •
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1. 2. 3. 4.
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5.1.2. Seven Wastes
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Also known as the Continuous Improvement Cycle: PLAN, DO, CHECK, ACT Is a standardized problem solving procedure Plan: what should be done Do: implement the plan Check: verify the result Act: correct problems that arise; document; standardize; if goal is not achieved: repeat the process Is connected with problem solving techniques like the 5 Ws
Processes are improved through the elimination of waste Seven wastes: 1. overproduction 2. over-processing 3. motion 4. transportation 5. waiting 6. inventory 7. defects/repair/rework Is applied in workshops
TOS_System_description_direct_090619.ppt
Benefits •
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Provides a standard template for how people should approach problems and improvements
Is a comprehensive method of consistently optimizing production processes
n o i t a n i
m i l E e t s a W
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Subsystem: Continuous Improvement Tool 5.1.3. 5 Why
Description •
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5.1.4. Process Map
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Benefits
“Ask the question: Why? 5 times” in order to understand what the root cause of a problem is Tool of the problem solving process and root cause analyses
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Determining root causes to problems
Graphic representation of the current state Should depict manpower, material, machinery and method (4 M) Describes how material, information and the process/people flow in an area Is relevant to the process Sets the parameter to measure the current and future state Part of the planning process for continuous improvement
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Visual aids in problem resolution and solving Provides visual methods for the interactions of people/process and material Reinforces understanding for everyone Supports planning for an improved state Enables consensus decision making
TOS_System_description_direct_090619.ppt
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Continuous Improvement
e t a R d n a m e D r e m o t s u C
n o i t a n i
m i l E e t s a W
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
Subsystem: Continuous Improvement Tool 5.1.5. Team-carried Continuous Improvement Workshops
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Team members discuss improvements themselves, e.g. in team workshops, discussions etc., and carry them out. Supervisors adopt useful ideas and support the team in working out their improvement suggestions (e.g. bonuses) The suggested improvements are discussed by staff and supervisors and put into practice Where required team members are trained in planning, methods and tools of the Team-carried Continuous Improvement Workshops Team-carried Continuous Improvement Workshops are supported and encouraged by experts
TOS_System_description_direct_090619.ppt
Benefits •
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Workshops help propagate a mindset of Continuous Improvement in the firm culture Gives staff an opportunity to learn together and work on Continuous Improvement Promotes sustainable mindset change
n o i t a n i
m i l E e t s a W
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
Subsystem: Continuous Improvement Tool Description I 5.1.6. Expert-carried Continuous Improvement Workshops
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Expert-done Continuous Improvement Workshops are generally implemented when intensive involvement of team members is not feasible, e.g. in planning of major restructuring Experts from all relevant sectors are involved Where relevant internal experts are supported by external experts Goal is same improvements as for Staff-carried Continuous Improvement Process (avoidance of waste) or implementing procedures into manufacturing system, e.g. routing Here too the involved team members must be informed before the changes are implemented Expert-carried continuous improvement workshops progress into staff-carried continuous improvement workshops
TOS_System_description_direct_090619.ppt
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
n o i t a n i
m i l E e t s a W
Benefits •
Improvement (S Q D C M) by reducing "waste" or applying MPS methods
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
y t i r a l C e l o R
t n e t m n e e v m l o o p v n l I e v e e e D y o d l p n a m E
Quality Focus & RobustProcesses andProducts
Standardization
e r u t c u r p t u S o r l a G n o k i r t o a z W i n a g r
O
s d s n e a n s e e r c a i w t c A a l r a P t n k r e o m n W o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c e o t x F r E e & m l a o n t r s e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P
w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
n o i t a n i
m i l E e t s a W
Subsystem: Continuous Improvement Tool 5.1.7.Continuous Improvement Workshops
Description •
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Generally a three to five day action oriented event in which improvements are implemented Before and after conditions are documented, measured, and reported Provides a platform and standard method for operators, supervisors, and engineers to focus, learn about waste elimination methods and activities and implement them usefully Workshops are initially conducted by expert facilitators, the facilitation has to be done later by in-plant facilitators or supervisors. All employees are informed the week ahead of the workshop (where workshop takes place) The follow up phase is needed to implement final actions
TOS_System_description_direct_090619.ppt
Benefits •
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Workshops help propagate a "waste elimination mindset" into the company culture Provides for a cross-functional team to learn and work together Improves employee involvement and cooperation Produces tangible cost reductions quickly
Truck Operating System (TOS) HumanInfrastructure
Waste Elimination
p i h s r e d a e L
y t i r a l C e l o R
t n e t m e n e v m l o p v o n l I e v e e e y D o d l p n a m E
e r u t c u r p t u S o l r a G n o k i r o t a z W i n a g r O
Quality Focus & RobustProcesses andProducts
Standardization
d s s n e a n s e e r c a i t w c A a l r a P t n k e r o m W n o r e i f a n v S E
s d o s h e t r e u M d d e c e z r o i d r P a d d n n a a t S
S 5 / s e u q i n h c e T l a u s i V
n o i t c e r r o C & n o i t c e t e D e u s s I k c i u Q
d n a s t c u d o r P & s e s s e c o r P t s u b o R
e c n a r u s s A y t i l a u Q e v i t n e v e r P
Just inTime
) l a s r n u c t e o x F E r e & l m a o n t s r e u t C I n (
g n i h t o o m S n o i t c u d o r P
n o i t c u d o r P l l u P
s e s s e c o r P w o l F s u o u n i t n o C
Continuous Improvement
e t a R d n a m e D r e m o t s u C
n o i t a n i m i l E e t s a W
Subsystem: Continuous Improvement Im provement Tool 5.1.8. Engineering change control 5.1.9. Practice Sharing Benchmark
Description •
Specified time intervals for the release of engineering changes
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Share experiences of completed / implemented waste reduction efforts Understanding of particularly effective solutions
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5.1.10. Simultaneous Engineering
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Planning and development processes performed in parallel Ideas and suggestions from operators and later users of the machinery are integrated into SE Involves all disciplines Special emphasis on involving machine tool suppliers Information is shared and accessible to all parties at every stage of the process
TOS_System_description_direct_090619.ppt
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Reduces product to market leadtime Leads to a stable process Good practices are propagated faster Sustainability strengthens CIP company wide Helps to break paradigms Supports standards throughout organization Reduces lead time Faster feedback from succeeding to preceding process Improves cooperation between engineering, production, suppliers, marketing, production control, etc Eliminates wait time between departments
Truck Operating System (TOS)
D List of Abbreviations
APA FIFO FMEA ISO 14000 JIT PDCA QS 9000 SE SPC SWI TPM VDA 6
Delivery Product Audit First in, First out Failure Method Effect Analysis Standard Series to Environmental Environmental Protection Just in Time Improvement Cycle: Plan, Do, Check, Act Quality Management System Simultaneous Engineering Statistical Process Control Standard Work Instruction Total Productive Maintenance Maintenance Quality Management System of the German Automotive Industry
TOS_System_description_direct_090619.ppt
Truck Operating System (TOS)
E Imprint
Publisher: Daimler AG Product and Production Planning CVD Dr. Martin Zimmermann HPC F303 D-70546 Stuttgart
January 2001
Name
Department
Horst Cronjäger Dieter Streitenberger Dr. Herbert Hörner Helmut Backes Frank Ehleiter Michael Humpert Dr. Wolf-Dieter Schultze-Scharnhorst Reiner Lehr Thomas Frisch Michael Thomas
PN/TP PN/TP P/PE P/PE K/SWI T WL PAP/AP PBE TPP/MP
Drucksachennummer: 888-00-001-02
TOS_System_description_direct_090619.ppt
Location 000 000 EvoBus EvoBus 037 072 065 096 034 000
