FIXED INNER RACE

PULL SYSTEM LOOP #1

#2 Triggering Point

#3 Schedule board

CONECTION POINT LOOP #2

START To Fixed Joint Assy

#1 Supermarket finish parts

#4 Supermarket to broaching

#7 Supermarket to final inspection

#6 FIFO to grinding machines

#5 Single point schedule

Jairton Amaral Maio/2010

FIXED INNER RACE

PULL SYSTEM LOOP #2
CONECTION POINT LOOP #3

#6 Heat Treatment

#5 Supermarket to heat treatment

Signal from Loop#1 step #4

Loop #1

#1 Interval

#2 Raw material supermarket

#4 Schedule board

#3Triggering Point

Jairton Amaral Maio/2010

FIXED INNER RACE

PULL SYSTEM LOOP #3
Empty container from Loop#2 step #5
Loop #2

#1 Empty container to CHQ

#2 CHQ warehouse

Full container to Loop#2 step #5

#4 POA warehouse

#3 Full container to POA

Jairton Amaral Maio/2010

Components Unit Cage Pull System Cell A

Start

Customer pulls

Supermarket is replenished

Fixed Joint Parts are ground

Empty boxes return

Demand is identified
Jairton Amaral Maio/2010

Looping #1

Components Unit Cage Pull System Cell A

Removes parts for grinding

Loading machine

Heat treated parts replenish flow rack

Empty boxes return

Go to Heat Treat FIFO

Empty boxes return to soft machining

Jairton Amaral Maio/2010 Parts are machined

Looping #2

Components Unit Cage Pull System Cell A

Formed parts are machined

Empty package returns

Formed parts are replenished

Demand is identified

Jairton Amaral Maio/2010

Looping #3

Components Unit Cage Pull System Cell A

Results
Lead Time DSA NRFT Schedule point OEE Downtime Days % ppm % % Before 7 60 1500 7 82 1,95 After 3 100 1300 1 87 0,85

Jairton Amaral Maio/2010

O que deu certo?

Gerenciamento visual

Logica intervalo para celula C

Adeso operadores Podemos medir o D S A Dimensionamento do supermercados Antecipao de problemas Administrao do fluxo

Jairton Amaral Maio/2010

Dificuldades?
Mquinas no flexiveis

Demandas de pico na junta fixa

Espao fsico menor que necessrio Comunicao com Charqueadas Ordem de produo x programa de produo Tempo de set-up tornos AIR Tempo de tratamento trmico Lay out GV
Jairton Amaral Maio/2010

Cronograma
Gaiola V - agosto (100%)

AIR

- junho (100%)

Jairton Amaral Maio/2010